Kawasaki Kcm WHEEL LOADER 65ZV-2 SHOP MANUAL 93207-00851 (1) by www.heydownloads.com

65ZV-2

93207-00851

SHOP MANUAL General Information Function & Structure

Printed in Japan (K) （アメリカ用）

93207-00851

November 2014

SHOP MANUAL WHEEL LOADER

65ZV-2 General Information Standard Measurement Values for Performance Check Function & Structure Check & Adjustment Powered by Isuzu 4HK1X Engine Serial No. 65J4-5001 and up

WARNING CALIFORNIA PROPOSITION 65

BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING ! CALIFORNIA Proposition 65 warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

"Perchlorate Material special handling may apply, See www.dtsc.ca.gov/hazardouswaste/perchlorate." Applicable parts : MCU (Machine Control Unit) Applicable state : California

93207-00851 November 2014

Foreword To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operator and Maintenance Manual. To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual. General Information Function and structure For the engine, refer to the engine Shop Manual provided by the engine manufacturer. The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service. This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or requests, please inform us.

Safety Symbols An accident may occur if you disregard safety rules. In this manual, several expressions are used according to levels of danger for inspection and repair work as shown below. Read the work procedures and cautions described in this manual, and take preventive measures against possible problems before starting service work.

DANGER This danger symbol identifies special warnings or procedures which, if not strictly observed, will result in death or serious injury.

WARNING This warning symbol identifies special warnings or procedures which, if not strictly observed, could result in death or serious injury.

CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, may result in minor or moderate injury.

IMPORTANT This important symbol identifies special instructions or procedures which, if not correctly followed, may result in serious machine damage.

We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident that is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when doing service work. Any technician that operates a refrigerant recovery and recycling machine must first be certified through an EPA approved testing program. More information is available at http://www.epa.gov/ozone/title6/608/technicians/608certs.html.

CONTENTS 00 General Information ......................................................................................................................................... 00-1 How to Use Manual ........................................................................................................................................... 00-2 Safety precautions ...................................................................................................................................... 00-2 Symbols ...................................................................................................................................................... 00-3 Outline ............................................................................................................................................................... 00-4 Layout of main components ........................................................................................................................ 00-4 Inspection and maintenance table .............................................................................................................. 00-5 Recommended Lubricants .......................................................................................................................... 00-8 Coolant ..................................................................................................................................................... 00-10 Lubrication chart ........................................................................................................................................00-11 Weight of main components ..................................................................................................................... 00-12 Bolt tightening torque ................................................................................................................................ 00-13 Hose band tightening torque ..................................................................................................................... 00-17 Liquid gasket and screw lock agent .......................................................................................................... 00-18 Cautions regarding welding repair service ................................................................................................ 00-20 03 Measurement for Performance Check ............................................................................................................. 03-1 Cautions on Safety ............................................................................................................................................ 03-2 Standard Measurement Values for Performance Check ................................................................................... 03-3 12 Function & Structure Chassis Group ................................................................................................................ 12-1 Front Chassis .................................................................................................................................................... 12-2 Loading linkage ........................................................................................................................................... 12-2 Loading linkage pin ..................................................................................................................................... 12-4 Rear Chassis .................................................................................................................................................... 12-5 Fuel tank (S/N 5001~5128) ......................................................................................................................... 12-5 Fuel tank (S/N 5129~) ................................................................................................................................. 12-6 Floor board mount ....................................................................................................................................... 12-7 Center Pin ......................................................................................................................................................... 12-8 Upper center pin ......................................................................................................................................... 12-8 Lower center pin ......................................................................................................................................... 12-8 Dust seal ..................................................................................................................................................... 12-9 13 Check & Adjustment Chassis Group ................................................................................................................ 13-1 Linkage Pin ....................................................................................................................................................... 13-2 Liner ............................................................................................................................................................ 13-2 Center Pin ......................................................................................................................................................... 13-4 Adjusting shim ............................................................................................................................................. 13-4

22 Function & Structure Power Group .................................................................................................................. 22-1 Power Line ........................................................................................................................................................ 22-2 Engine / Transmission ....................................................................................................................................... 22-3 Engine / transmission mount ....................................................................................................................... 22-3 Radiator ............................................................................................................................................................. 22-4 Radiator mount ........................................................................................................................................... 22-5 Propeller Shaft .................................................................................................................................................. 22-6 Second propeller shaft assembly ................................................................................................................ 22-7 Third propeller shaft assembly .................................................................................................................... 22-8 Axle Assembly ................................................................................................................................................... 22-9 Axle Support .................................................................................................................................................... 22-10 Differential Gear .............................................................................................................................................. 22-12 Function of T.P.D ....................................................................................................................................... 22-16 Operation of T.P.D ..................................................................................................................................... 22-17 Limited Slip Differential (option) ................................................................................................................ 22-18 23 Check & Adjustment Power Group .................................................................................................................. 23-1 Engine ............................................................................................................................................................... 23-2 Measuring engine speed ............................................................................................................................. 23-2 Measuring engine oil pressure .................................................................................................................... 23-2 Propeller Shaft .................................................................................................................................................. 23-3 Propeller shaft phase .................................................................................................................................. 23-3 Second propeller shaft alignment ............................................................................................................... 23-3 Tightening torque ........................................................................................................................................ 23-4 32 Function & Structure Torque Converter and Transmission Group ................................................................... 32-1 Torque Converter .............................................................................................................................................. 32-2 Torque converter structure .......................................................................................................................... 32-2 Power flow path .......................................................................................................................................... 32-2 Torque multiplication ................................................................................................................................... 32-2 Torque Converter Gear Pump ........................................................................................................................... 32-3 Pump specifications .................................................................................................................................... 32-3

Transmission ..................................................................................................................................................... 32-4 Clutch combination ..................................................................................................................................... 32-4 Shift lever position ....................................................................................................................................... 32-4 Downshift button operation ......................................................................................................................... 32-4 Gear train and number of teeth ................................................................................................................... 32-5 Valve location .............................................................................................................................................. 32-6 Clutch specifications ................................................................................................................................... 32-8 Clutch Pack ..................................................................................................................................................... 32-10 Forward and reverse clutch ...................................................................................................................... 32-10 1st and 2nd speed clutch ...........................................................................................................................32-11 3rd and 4th speed clutch ........................................................................................................................... 32-12 Power Flow Path in the Transmission ............................................................................................................. 32-13 Hydraulic System Diagram ............................................................................................................................. 32-18 Hydraulic Circuit Diagram ............................................................................................................................... 32-19 Oil Flow ........................................................................................................................................................... 32-20 Oil flow in the torque converter line ........................................................................................................... 32-20 Oil flow to the clutches .............................................................................................................................. 32-20 T/C and T/M Oil Circulation ............................................................................................................................. 32-21 Control Valve ................................................................................................................................................... 32-23 Oil port layout ............................................................................................................................................ 32-24 Modulation Mechanism ................................................................................................................................... 32-25 Clutch control oil pressure curve ............................................................................................................... 32-25 Modulation mechanism operation ............................................................................................................. 32-26 Accumulator .................................................................................................................................................... 32-29 Accumulator for 1st and 2nd speed clutch ................................................................................................ 32-29 Clutch Solenoid Valve ..................................................................................................................................... 32-30 For forward/reverse and speed clutches ................................................................................................... 32-30 33 Check & Adjustment Torque Converter and Transmission Group ................................................................... 33-1 Clutch Oil Pressure ........................................................................................................................................... 33-2 Measuring clutch oil pressure ..................................................................................................................... 33-2 42 Function & Structure Hydraulic Group ............................................................................................................. 42-1 Flushing Hydraulic Circuit ................................................................................................................................. 42-2 Purpose of flushing ..................................................................................................................................... 42-2 Cautions on Hydraulic Parts Replacement ....................................................................................................... 42-3

Hydraulic Circuit Symbols ................................................................................................................................. 42-4 Hydraulic lines ............................................................................................................................................. 42-4 Pumps & motors ......................................................................................................................................... 42-4 Cylinders ..................................................................................................................................................... 42-4 Operation methods ..................................................................................................................................... 42-5 Pressure control valve ................................................................................................................................ 42-5 Flow control valve ....................................................................................................................................... 42-5 Directional control valve .............................................................................................................................. 42-6 Check valve ................................................................................................................................................ 42-6 Miscellaneous hydraulic symbols ................................................................................................................ 42-7 Hydraulic System Operation ............................................................................................................................. 42-8 Hydraulic system operation outline ............................................................................................................. 42-8 Layout of Hydraulic Units ................................................................................................................................ 42-10 Hydraulic Tank ..................................................................................................................................................42-11 Hydraulic Tank (S/N 5001~5200) ...............................................................................................................42-11 Hydraulic tank breather valve (tank cap)(S/N 5001~5200) ....................................................................... 42-12 Hydraulic Tank (S/N 5201~) ...................................................................................................................... 42-13 Hydraulic tank breather valve (tank cap)(S/N 5201~) ............................................................................... 42-14 Hydraulic tank specifications ..................................................................................................................... 42-15 Hydraulic oil level check ............................................................................................................................ 42-16 Hydraulic Pump ............................................................................................................................................... 42-17 Hydraulic pump specifications .................................................................................................................. 42-17 Hydraulic pump principle ........................................................................................................................... 42-18 Hydraulic pump wear plate ....................................................................................................................... 42-19 Hydraulic pump bushing lubrication .......................................................................................................... 42-19 Hydraulic Cylinder ........................................................................................................................................... 42-20 Boom cylinder ........................................................................................................................................... 42-20 Bucket cylinder .......................................................................................................................................... 42-21 Steering cylinder ....................................................................................................................................... 42-21 Hydraulic cylinder specifications ............................................................................................................... 42-22 Loading System .............................................................................................................................................. 42-23 Reducing Valve (for Pilot Pressure) ................................................................................................................ 42-24

Pilot Valve (TH40MS) ...................................................................................................................................... 42-25 Pilot valve specifications ........................................................................................................................... 42-26 Pilot valve performance chart ................................................................................................................... 42-26 Pilot valve operation .................................................................................................................................. 42-28 Multiple Control Valve (KML22/2T) ................................................................................................................. 42-30 Multiple control valve specifications .......................................................................................................... 42-31 Multiple control valve main relief valve ..................................................................................................... 42-32 Multiple control valve overload relief valve (with make-up function) ......................................................... 42-34 Multiple control valve make-up valve ........................................................................................................ 42-36 Multiple control valve bucket spool ........................................................................................................... 42-37 Multiple control valve boom spool ............................................................................................................. 42-39 Adapter (Orifice) .............................................................................................................................................. 42-42 Ride Control (OPT) ......................................................................................................................................... 42-43 Ride control hydraulic circuit ..................................................................................................................... 42-44 Ride control function ................................................................................................................................. 42-44 Ride control operation ............................................................................................................................... 42-45 Ride control valve assembly ..................................................................................................................... 42-47 Accumulator (for ride control) .................................................................................................................... 42-52 Steering System .............................................................................................................................................. 42-53 Priority Valve ................................................................................................................................................... 42-55 Priority valve operation ............................................................................................................................. 42-56 Orbitrol® .......................................................................................................................................................... 42-59 Valve System ............................................................................................................................................ 42-59 Orbitrol® structure ..................................................................................................................................... 42-59 Orbitrol® specification ............................................................................................................................... 42-60 Orbitrol® operation .................................................................................................................................... 42-61 Orbitrol® feed-back mechanism operation ................................................................................................ 42-63 Steering speed and flow rate control ........................................................................................................ 42-64 Hydraulic pump oil amount and steering force .......................................................................................... 42-64 Oil flow change when Q/Amp. is operated ................................................................................................ 42-65 Orbit rotor operation principle ................................................................................................................... 42-66 Auxiliary valves ......................................................................................................................................... 42-67 Emergency check valve ............................................................................................................................ 42-69 Inlet check valve ....................................................................................................................................... 42-69 Accumulator .................................................................................................................................................... 42-70

Efficient Loading System (OPT) ...................................................................................................................... 42-72 Efficient loading system outline ................................................................................................................. 42-72 Mounting of the ELS valve ........................................................................................................................ 42-73 Mounting of the variable kickout sensor .................................................................................................... 42-75 Efficient loading system operation ............................................................................................................ 42-76 Fan Motor System ........................................................................................................................................... 42-78 Mounting of fan motor ............................................................................................................................... 42-78 Fan Motor Line ................................................................................................................................................ 42-79 Hydraulic circuit (fan motor normal rotation) ............................................................................................. 42-82 Fan motor (S/N 5001~5054) ..................................................................................................................... 42-85 Fan motor (S/N 5055~) ............................................................................................................................. 42-87 Reversing Fan Motor Line ............................................................................................................................... 42-90 Reversing fan motor function .................................................................................................................... 42-90 Reversing fan motor .................................................................................................................................. 42-90 Reversing fan control chart ....................................................................................................................... 42-91 Hydraulic circuit (Reverse rotation) ........................................................................................................... 42-92 Secondary Steering (OPT) .............................................................................................................................. 42-93 Secondary steering operation ................................................................................................................... 42-94 Secondary steering motor and pump ........................................................................................................ 42-95 43 Check & Adjustment Hydraulic Group .............................................................................................................. 43-1 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ........................................... 43-2 Loading circuit relief valve setting pressures .............................................................................................. 43-2 Ride control circuit reducing valve setting pressures (OPT) ....................................................................... 43-6 Steering circuit relief valve setting pressures .............................................................................................. 43-8 Hydraulic Cylinder ............................................................................................................................................43-11 Cylinder natural drift ...................................................................................................................................43-11 52 Function & Structure Brake Group ................................................................................................................... 52-1 Brake System Outline ....................................................................................................................................... 52-2 Service brake .............................................................................................................................................. 52-2 Parking brake .............................................................................................................................................. 52-2 Adjustment of axle internal pressure ........................................................................................................... 52-2 Brake Units Layout ............................................................................................................................................ 52-3 Unloader Valve .................................................................................................................................................. 52-4 Unloader valve operation ............................................................................................................................ 52-5 Valve Unit .......................................................................................................................................................... 52-6

Accumulator ...................................................................................................................................................... 52-8 In-Line Filter ...................................................................................................................................................... 52-9 Brake Valve ..................................................................................................................................................... 52-10 Brake valve performance chart ..................................................................................................................52-11 Brake valve outline .................................................................................................................................... 52-12 Service Brake .................................................................................................................................................. 52-14 Service brake operation ............................................................................................................................ 52-14 Service brake friction plate ........................................................................................................................ 52-15 Service brake steel plate ........................................................................................................................... 52-15 Brake circuit air bleeding procedure ......................................................................................................... 52-16 Parking Brake ................................................................................................................................................. 52-17 Parking brake operation ............................................................................................................................ 52-18 Parking brake solenoid valve .................................................................................................................... 52-19 Parking Brake Manual Release ...................................................................................................................... 52-20 Parking Brake Spring Chamber ...................................................................................................................... 52-22 Brake Circuit Check Valve ............................................................................................................................... 52-23 Pressure Sensor (for stop lamp and declutch) ................................................................................................ 52-24 Pressure sensor (for Declutch) ................................................................................................................. 52-24 Pressure sensor (for stop lamp) ................................................................................................................ 52-24 53 Check & Adjustment Brake Group ................................................................................................................... 53-1 Brake Circuit Oil Pressure ................................................................................................................................. 53-2 Unloader valve setting pressure ................................................................................................................. 53-2 Brake valve oil pressure .............................................................................................................................. 53-4 Service Brake .................................................................................................................................................... 53-6 Service brake performance check .............................................................................................................. 53-6 Service brake friction plate wear measurement .......................................................................................... 53-7 Parking Brake ................................................................................................................................................... 53-8 Parking brake performance check .............................................................................................................. 53-8 Parking brake clearance adjustment ........................................................................................................... 53-9

62 Function & Structure Electrical Group .............................................................................................................. 62-1 How to Use Electrical Wiring Diagram .............................................................................................................. 62-2 Electrical Cable Color Codes ............................................................................................................................ 62-3 Electrical Circuit Symbols .................................................................................................................................. 62-4 Sensor Mount .................................................................................................................................................... 62-5 Fuse .................................................................................................................................................................. 62-6 Fuse box ..................................................................................................................................................... 62-6 Fusible link .................................................................................................................................................. 62-8 Engine Start Circuit ........................................................................................................................................... 62-9 Engine start circuit diagram ........................................................................................................................ 62-9 Neutral starter ........................................................................................................................................... 62-10 Starter switch .............................................................................................................................................62-11 Battery relay .............................................................................................................................................. 62-12 Alternator L terminal wire .......................................................................................................................... 62-12 Diode unit .................................................................................................................................................. 62-13 Neutral relay .............................................................................................................................................. 62-14 Safety relay ............................................................................................................................................... 62-15 Power Generating/Charging Circuit ................................................................................................................ 62-16 Alternator .................................................................................................................................................. 62-16 ECM (Engine Controller) ................................................................................................................................. 62-17 Function of ECM ....................................................................................................................................... 62-17 Connection diagram .................................................................................................................................. 62-17 Monitor lamp test ...................................................................................................................................... 62-18 Diagnosis trouble code (DTC) information ................................................................................................ 62-19 Accelerator pedal ...................................................................................................................................... 62-22 Transmission Control Circuit and Monitor Circuit ............................................................................................ 62-24 Machine control unit (MCU) ...................................................................................................................... 62-24 Machine control unit (MCU) connection diagram (S/N 5001~5400) ......................................................... 62-26 Machine control unit (MCU) connection diagram (S/N 5401~) ................................................................. 62-28 Machine control unit (MCU) function ......................................................................................................... 62-30 Adjustable declutch preset switch ............................................................................................................. 62-35 Monitoring system ..................................................................................................................................... 62-42

Instrument Panel and Switch .......................................................................................................................... 62-44 Instrument panel ....................................................................................................................................... 62-44 Instrument panel rear surface ................................................................................................................... 62-46 Gauge circuit ............................................................................................................................................. 62-48 Fuel level sensor ....................................................................................................................................... 62-50 MODM ............................................................................................................................................................. 62-53 MODM function ......................................................................................................................................... 62-53 Monitor Changeover ................................................................................................................................. 62-53 Information Monitor ................................................................................................................................... 62-56 Replacement Monitor ................................................................................................................................ 62-60 Fault Log Monitor ...................................................................................................................................... 62-66 Input/Output Monitor ................................................................................................................................. 62-73 Parameter Setting Monitor ........................................................................................................................ 62-77 Specification Setting Monitor .................................................................................................................... 62-86 Electrical Detent Circuit ................................................................................................................................... 62-92 Bucket leveler ........................................................................................................................................... 62-92 Detent solenoid ......................................................................................................................................... 62-94 Lift kickout & lower kickout ........................................................................................................................ 62-95 Sensor assy .............................................................................................................................................. 62-96 Detent solenoid ......................................................................................................................................... 62-98 Preset height adjustment .......................................................................................................................... 62-98 Diode ............................................................................................................................................................... 62-99 Diode check method ............................................................................................................................... 62-100 Caution for diode check method ............................................................................................................. 62-100 Surge voltage and surge suppression diodes ......................................................................................... 62-102

72 Function & Structure Operator Station Group .................................................................................................. 72-1 Air Conditioner (S/N 5001~5050) ...................................................................................................................... 72-2 Air conditioning systems ............................................................................................................................. 72-2 Air conditioning unit ..................................................................................................................................... 72-2 Bergstrom air conditioner structure ............................................................................................................. 72-3 134A refrigerant compressor ...................................................................................................................... 72-6 Condenser .................................................................................................................................................. 72-8 Thermostatic expansion valve .................................................................................................................... 72-8 Receiver / Drier ........................................................................................................................................... 72-9 Evaporator core and temperature sensor ................................................................................................. 72-10 Pressure switch ......................................................................................................................................... 72-12 Defroster/Operator ventilation and heater valve actuator motors ............................................................. 72-13 Control panel ............................................................................................................................................. 72-14 Panel switches .......................................................................................................................................... 72-18 Air conditioner troubleshooting ................................................................................................................. 72-19 Checking voltage at connectors ................................................................................................................ 72-24 Checking actuators ................................................................................................................................... 72-25 Maintenance ............................................................................................................................................. 72-26 A/C Charging ............................................................................................................................................ 72-32 Final inspection ......................................................................................................................................... 72-34 Appendix ................................................................................................................................................... 72-35 Air Conditioner (S/N 5051~) ............................................................................................................................ 72-37 Denso air conditioner components ........................................................................................................... 72-37 Denso air conditioner structure ................................................................................................................. 72-38 Function of cooling mechanism ................................................................................................................ 72-43 Cooling circuit ........................................................................................................................................... 72-46 Electrical circuit ......................................................................................................................................... 72-47 Air conditioner functions of components ................................................................................................... 72-48 Charge of refrigerant ................................................................................................................................. 72-76 Air conditioner troubleshooting ................................................................................................................. 72-93

73 Check & Adjustment Operator Station Group .................................................................................................. 73-1 Air Conditioner .................................................................................................................................................. 73-2 Adjustment of lubricating oil quantity when components of air conditioner are replaced ............................ 73-2 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................... 73-5 Compressor V-belt adjustment (S/N 5001~5050) (Bergstrom) ................................................................... 73-6 Compressor V-belt adjustment (S/N 5051~) (DENSO) ............................................................................... 73-8 Parts to be replaced periodically ............................................................................................................... 73-10 92 Drawing & Diagrams ........................................................................................................................................ 92-1 Axle Assembly .................................................................................................................................................. 92-2 Torque Converter and Transmission ................................................................................................................. 92-4 Hydraulic & Brake Circuit .................................................................................................................................. 92-5 Brake Circuit ..................................................................................................................................................... 92-6 Electrical Wiring Diagram (1/4) (S/N 5001~5050) ............................................................................................. 92-7 Electrical Wiring Diagram (2/4) (S/N 5001~5050) ............................................................................................. 92-8 Electrical Wiring Diagram (3/4) (S/N 5001~5050) ............................................................................................. 92-9 Electrical Wiring Diagram (4/4) (S/N 5001~5050) ........................................................................................... 92-10 Electrical Wiring Diagram (1/4) (S/N 5051~5100) ............................................................................................92-11 Electrical Wiring Diagram (2/4) (S/N 5051~5100) ........................................................................................... 92-12 Electrical Wiring Diagram (3/4) (S/N 5051~5100) ........................................................................................... 92-13 Electrical Wiring Diagram (4/4) (S/N 5051~5100) ........................................................................................... 92-14 Electrical Wiring Diagram (1/4) (S/N 5101~5400) ........................................................................................... 92-15 Electrical Wiring Diagram (2/4) (S/N 5101~5400) ........................................................................................... 92-16 Electrical Wiring Diagram (3/4) (S/N 5101~5400) ........................................................................................... 92-17 Electrical Wiring Diagram (4/4) (S/N 5101~5400) ........................................................................................... 92-18 Electrical Wiring Diagram (1/4) (S/N 5401~) ................................................................................................... 92-19 Electrical Wiring Diagram (2/4) (S/N 5401~) ................................................................................................... 92-20 Electrical Wiring Diagram (3/4) (S/N 5401~) ................................................................................................... 92-21 Electrical Wiring Diagram (4/4) (S/N 5401~) ................................................................................................... 92-22 Electrical Wiring Diagram ................................................................................................................................ 92-23 Way of looking at connectors .................................................................................................................... 92-23 Electrical wiring diagram abbreviation chart ................................................................................................... 92-25 Electrical Wiring Diagram (CAB) ..................................................................................................................... 92-27 Electrical Connection Diagram (1/2) (S/N 5001~5050) ................................................................................... 92-30 Electrical Connection Diagram (2/2) (S/N 5001~5050) ................................................................................... 92-31 Electrical Connection Diagram (1/2) (S/N 5051~5100) ................................................................................... 92-32

Electrical Connection Diagram (2/2) (S/N 5051~5100) ................................................................................... 92-33 Electrical Connection Diagram (1/2) (S/N 5101~5400) ................................................................................... 92-34 Electrical Connection Diagram (2/2) (S/N 5101~5400) ................................................................................... 92-35 Electrical Connection Diagram (1/2) (S/N 5401~) ........................................................................................... 92-36 Electrical Connection Diagram (2/2) (S/N 5401~) ........................................................................................... 92-37 Electrical Connection (Cabin Air Conditioner) (S/N 5001~5050) .................................................................... 92-38 Electrical Wiring Diagram (Cabin Air Conditioner) (S/N 5051~) ...................................................................... 92-39 Electrical Circuit Diagram (Cabin Air Conditioner) (S/N 5051~) ...................................................................... 92-40 Equipment Operation Table (Cabin Air Conditioner) (S/N 5051~) .................................................................. 92-41 Electrical Equipment Layout ............................................................................................................................ 92-42 Outline of MODM (Machine Operation Diagnostic Module) Operation ........................................................... 92-59 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ................................................... 92-68

65ZV-2 US 00-1 00 General Information

00 General Information How to Use Manual ................................................. 00-2 Outline ..................................................................... 00-4

65ZV-2 US 00-2 00 General Information How to Use Manual

How to Use Manual Safety precautions

- Contact tire manufacturer's local dealer for tire servicing and changing.

The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below.

- Always store the tools in good condition, and use them properly.

- This manual is intended for properly trained and equipped service technicians. - Any work on the machine must be performed by the trained personnel only. - Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine. - Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles. - Place the machine on level and solid ground, and place chocks against the wheels to prevent movement. - Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" tag to the steering wheel. - Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe. - Be sure to apply the articulation stopper before starting work. - While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks. - When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate cribbing under the unit to prevent unexpected dropping. - Do not start to work in an enclosed area if adequate ventilation is not provided. - To remove a heavy unit (20 kg (40 lbs) or more), be sure to use a crane or other lifting device. - Just after stopping operation, be careful not to directly touch a hot component. You may get burned.

- Keep the work area clean. Clean up spills immediately. - Avoid the use of flammable solvents and cleaners. - When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud. - Use safe work platforms to reach higher areas of the machine. - Any technician that operates a refrigerant recovery and recycling machine must first be certified through an EPA approved testing program. More information is available at http://www.epa.gov/ ozone/title6/608/technicians/608certs.html.

65ZV-2 US 00-3 00 General Information How to Use Manual

Symbols For safe and effective service work, the following symbols are used for notes and useful information in this manual. Symbol

Item

Description

Reference

Shows the condition or procedure that will be useful or efficient in doing service work.

Weight

Shows the weight of a part or unit. The weight should be considered in selecting wire rope or cable for slinging work or determining the working posture.

Tightening Shows the tightening torque of a section that should torque be carefully tightened during assembly work.

Coating

Shows the type of coating or adhesive and the coating section.

Oil or water supply

Shows the oil or water supply port and the refill amount.

Drainage

Shows the oil or water drain port and the drain amount.

IMPORTANT If the specified conditions are not satisfied or the specified procedure is not observed, there is a strong possibility that the product will be damaged or the performance of the product will be reduced. The message shows the preventive measures.

Abbreviation To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the following abbreviation list. Additional abbreviations are listed on page 92-25. E/G ........... Engine T/C ........... Torque converter T/M ........... Transmission SOL ........... Solenoid valve SW ........... Switch F ........... Front or Forward A/M ........... Auto/Manual B ........... Battery R ........... Rear or Reverse

RH ............Right hand side LH ............Left hand side H ............High L ............Low GND ............Ground OPT ............Option Assy ............Assembly 1st ............1st speed 2nd ............2nd speed

3rd ............3rd speed 4th ............4th speed M/C ............Machine min-1 ............RPM ELS ............Efficient loading system MODM ........Machine operation diagnostic module MCU ...........Machine control unit

65ZV-2 US 00-4 00 General Information Outline

Outline Layout of main components 24

23 (S/N ~5136) (S/N 5137~) 23

25 18

14 2

23 (S/N ~5136)

5 13

9 K65V2U00001

10. Parking brake 19. Transmission control valve 1. Engine assembly (Isuzu 4HK1X) 11. Air cleaner 20. Bucket cylinder 2. Transmission/Torque converter assy 21. Hoist cylinder 3. Radiator assembly (including air cooler) 12. Muffler 13. Fan motor 22. Steering cylinder 4. Hydraulic oil cooler (air-to-oil type) 14. Hydraulic pump 23. Accumulator (for steering) 5. T/C oil cooler 15. Multiple (loader) control valve 24. Pump unit (for secondary 6. 2nd propeller shaft 16. Orbitrol® steering) (OPT) 7. 3rd propeller shaft 25. ELS (OPT) 8. Front axle assembly 17. Priority valve 9. Rear axle assembly 18. Pilot valve (for loading)

65ZV-2 US 00-5 00 General Information Outline

Inspection and maintenance table IMPORTANT Refer to Operation & Maintenance Manual for maintenance procedures.

Severe application require more frequent maintenance. Severe conditions include heavy dust, extremely abrasive material, caustic chemicals, extremely wet conditions or abnormally hot or cold ambient temperatures. : First time replacement or cleaning only Operating hours

Section

Item for check 10

250

500

1000

2000

Check Engine Oil Level Check Engine Coolant Level Check Warning Lamps Check Exhaust Gas Drain Water and Sediment from Fuel Filter Check Fuel Level Check and Adjust Drive Belts Check Air Intake System Check Cooling Fan Drain Water and Sediment from Fuel Tank Replace Engine Oil and Oil Filter Cartridge Engine Replace Fuel Filter Elements Clean Electromagnetic Fuel Pump Filter Clean Fuel Feed Pump Strainer Check Engine Compression Pressure Check and Adjust Valve Lash Clearance Clean Fuel Tank Replace Electromagnetic Fuel Pump Filter Element Clean or Replace Air Cleaner Element Clean Radiator / Air cooler / Hydraulic oil cooler Fins Clean or Replace Air Cleaner Element Replace Coolant Check Transmission Oil Level Transmission & Torque Converter

Replace Transmission Oil Filter Cartridge Replace Transmission Oil Clean or Replace Transmission Breather

After six cleanings or once a year Every 2 years or 3000 hours

When Required

65ZV-2 US 00-6 00 General Information Outline : First time replacement or cleaning only Operating hours Section

Item for check 10

250

500

1000

Check Tire for Damage, Air and Tread Depth Greasing (Axle support) Check Tire Air Pressure Check Differential Gear Oil Greasing (Pillow block bearing unit) Axle system

Check Tightness of Wheel Bolts Check Tightness of Axle Mount Bolts Greasing (2nd Propeller Shaft Spline) Replace Differential Gear Oil Greasing (2nd Propeller Shaft)

Every 12000 hours

Greasing (3rd Propeller Shaft)

Every 12000 hours

Check Steering Wheel Operation Steering system Greasing (Steering Cylinder) Check Service Brake Operation Check Parking Brake Operation Adjust Parking Brake Lining Brake system Check Service Brake Disk Wear Check Brake Accumulator Clean Filter for Brake Line Check Hydraulic Oil Level Greasing Replace Hydraulic Oil Return Filter Replace Hydraulic Oil, Clean Filter Loading system Replace Filter in the Hydraulic Tank Cap (S/N 5001~5200) Replace Filter in the Hydraulic Tank Breather Valve (S/N 5201~) Replace Bucket Teeth (option) Replace Cutting Edge Adjust and Check Rear View Mirrors ROPS (Roll Over Protective Structure) Cab Check Seat Belt Restraint Greasing (Center Pin) Chassis Check Ride Control Accumulator (option) Replace Seat Belt and Tether Check Windshield Washer Fluid Check Bucket Stopper

2000

When Required

65ZV-2 US 00-7 00 General Information Outline : First time replacement or cleaning only Operating hours Section

Item for check 10

250

500

1000

2000

Check Monitor Panel Operation Check Horn Operation Electrical system

Check Back-up Alarm Operation Check Wiring Harnesses Check Battery Electrolyte Level Check or Replace Fuses Check and Adjust Air Conditioner Belt Clean Air Conditioner Filter Element Check Air Conditioner Refrigerant

Air Conditioner Replace Air Conditioner Filter Elements Clean Air Conditioner Condenser Replace Air Conditioner Receiver Dryer Others

Walk-Around Inspection

Every 3 years or 6000 hours

When Required

65ZV-2 US 00-8 00 General Information Outline

Recommended Lubricants

Engine

Transmission

Ambient Temperature

Refill capacity (Approximate)

Kind of Oil

18.6 liter (4.9 gal)

Engine oil (CF4)

20 liter (5.3 gal)

-2ºF -4 -30ºC -20

2 Hydraulic oil

Differential & Planetary

Front: 25 liter (6.6 gal) Rear: 25 liter (6.6 gal)

Mobil TRANS HD-50 Valvoline DT50

Fuel tank

210 liter (55.5 gal)

Diesel fuel

50 10

68 20

86 104 30 40

SAE15W-40

Change Interval (Hours) 500

Multi-Purpose ATF SAE10W Mobil TRANS HD-10

Mobil TRANS HD-10 Valvoline DT10

1 70 liter (18.5 gal)

32 0

SAE10W-30

ATF Engine oil (CD)

Hydraulic tank

14 -10

1,000

Valvoline DT10

ISO VG32 ISO VG46

Mobil TRANS HD-50 Valvoline DT50

2,000

ASTM D975 No.1 ASTM D975 No.2

daily

Note: 1 shows "Hydraulic tank oil capacity at level gauge center." Engine

Use oil that meets engine oil classification API CF4.

Transmission

Use engine oil classification API "CD". Mobil TRANS HD-10. Valvoline DT10. Multi-purpose Automatic Transmission Fluid. Never mix engine oil, Mobil TRANS HD-10, Valvoline DT10 and/or ATF.

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, antifoam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure. 2. In a case that fire-resistant fluid is to be used in the hydraulic circuit, replace hydraulic pump every 6,000 hrs operation. Be sure to use ISO VG32 when the temperature is below 0 ºF (-15 ºC). When changing the hydraulic oil from ISO VG46 to ISO VG32, the brakes must be bled to fully circulate the new oil, or brake problems could occur.

Differential & Planetary

Use Mobil TRANS HD-50, Valvoline DT50 or equivalent with 5% "Antichatter" additive or friction modifier.

Lubricating Grease

Use multipurpose-type EP/MOLY grease for most applications. NLGI NO.2 grease is suitable for most temperatures. NLGI NO.1 or NO.0 grease for extremely low temperature. Use lithium base grease for universal joints and a propeller shaft spline.

65ZV-2 US 00-9 00 General Information Outline

Diesel Fuel

Requirements for diesel fuel Specifications Flash Point

ºC.

Grade No.2-D

0.05

max.

288

338

min.

1.3

1.9

max.

2.4

4.1

0.01

min.

Water and Sediment % vol.

max

Distillation Temperature

90% vol.

ºC

recovered

Kinematic Viscosity mm2/s at 40ºC

Ash % mass

Grade No.1-D

max.

Sulfur % mass

max.

0.50

Cetane Number

min.

0.15

0.35

Carbon residue on 10% distillation residue % mass

max.

65ZV-2 US 00-10 00 General Information Outline

Coolant Coolant specification The machine is originally filled with Long Life Coolant (non-Amin type ethylene glycol) which need not be replaced for the first two years or 3000 hours. Do not use Amin type Long Life Coolant in cooling system. It may cause a corrosion against radiator or heater core. If standard antifreeze (not Long Life Coolant) is used for the replacement, it should be replaced every six months.

Recommended mixture of antifreeze Expected Minimum Ambient Temperature

-35ºC

-30ºC

-25ºC

-20ºC

-15ºC

Pure Water

(liter)

14.1

15.6

17.1

18.6

20.1

Antifreeze

(liter)

15.9

14.4

12.9

11.4

9.9

Mixture Ratio (%)

- Too much antifreeze in the coolant mixture may cause engine overheating. Keep 33% antifreeze mixture (same as the mixture for a minimum ambient temperature of -15ºC) if the engine overheats in a high ambient temperature. - Do not use hard water or water with high levels of calcium and magnesium ions as the coolant water.

IMPORTANT Do not mix different brands of antifreeze because they each contain special additives. Careless mixing often diminishes the effect of these additives and causes packing damage or water leakage.

65ZV-2 US 00-11 00 General Information Outline

Lubrication chart HYDRAULIC TANK

DIFF & GEAR BOX

2ND PROPELLER SHAFT

GO TRANSMISSION

DIFF & GEAR BOX

EVERY 12000Hr

EVERY 2000Hr

EVERY 1000Hr

ENGINE OIL PAN

LINK SYSTEM

EVERY 500Hr

PILLOW UNIT GO

EVERY 250Hr

CENTER PIN

EVERY 50Hr

G TO

EVERY DAY

G AXLE SUPPORT

G BUCKET

G G

STEERING CYLINDER

2ND PROPELLER SHAFT

G 3RD PROPELLER SHAFT K85V2U00001

Grease point

G Multipurpose grease

HO Hydraulic oil

Check and add if necessary

GO Gear oil

TO Engine oil

Oil replacement

EO Engine oil

65ZV-2 US 00-12 00 General Information Outline

Weight of main components

Part name

Approx. weight (kg)

Approx. weight (lb)

Bucket

730

1,610

GSC bucket

Boom

670

1,480

Standard

Item Unit name

"Z" -Lever

180/pc

400/pc

Link (Bucket to Lever)

40/pc

90/pc

Engine room assembly

240

530

Including screen board

Hydraulic tank

100

220

Excluding oil Excluding fuel

Chassis

Deck

Power line

Hydraulic system

Other

Remarks

Fuel tank

150

330

Floor board

165

365

Cab (ROPS)

500

1,100

Left side

With handrail

Right side

With handrail

Front chassis

945

2,085

Rear chassis

845

1,865

Counter weight

425

940

Engine

480

1,060

Excluding oil

Radiator assembly

130

285

Excluding water and oil

Torque converter oil cooler

Excluding oil

Transmission

535

1,180

Excluding oil

Second propeller shaft

Third propeller shaft

Front axle assembly

525

1,160

Excluding tires and oil

Rear axle assembly

670

1,480

Excluding tires and oil (Including axle support)

Differential

145

320

Multiple control valve

Pilot valve

Priority valve

Gear pump

Fan motor

Triple pump

Boom cylinder

95/pc

210/pc

Excluding oil

Bucket cylinder

105/pc

230/pc

Excluding oil

Steering cylinder

20/pc

45/pc

Excluding oil

Tire

200/pc

440/pc

With rim (17.5-25-12PR); No Hydro Inflation

Battery

30/pc

66/pc

65ZV-2 US 00-13 00 General Information Outline

Bolt tightening torque Hexagon bolt 1. Thread type Metric thread, Unified thread 2. Bolt strength 8.8 (8T) ~ 10.9 (11T) 3. Thread pitch Metric thread: Coarse pitch thread (C), fine pitch thread (F) Unified thread: Coarse pitch thread (UNC), fine pitch thread (UNF) (N-m) Bolt size Type

Nominal dimension

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

M10

M12

M14

M16

M18 Metric thread

M20

M22

Unified thread

Bolt strength

(F) 1.25

132

(F) 1.25

142

206

(F) 1.5

152

221

216

314

(F) 1.5

226

330

299

436

(F) 1.5

324

476

417

608

(F) 1.5

451

662

559

814

(F) 1.5

598

878

721

1,030

(F) 2.0

770

1,128

1,030

1,520

(F) 2.0

1,128

1,618

1,422

2,109

(F) 2.0

1,569

2,256

1,912

2,844

(F) 2.0

2,059

3,040

M24

M27

M30

M33

5/16

18 UNC

3/8

16 UNC

7/16

14 UNC

103

1/2

13 UNC

103

147

9/16

12 UNC

147

216

5/8

11 UNC

201

294

3/4

10 UNC

358

525

7/8

9 UNC

554

809

8 UNC

868

1,275

Note: Tighten the bolts according to the above list, unless otherwise specified.

65ZV-2 US 00-14 00 General Information Outline

(kgf-m) Bolt size Type

Nominal dimension

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

2.7

3.9

M10

M12

M14

M16

M18 Metric thread

M20

M22

Unified thread

Bolt strength

5.4

7.8

(F) 1.25

5.6

8.2

9.2

13.5

(F) 1.25

9.8

14.5

21.0

(F) 1.5

15.5

22.5

22.0

32.0

(F) 1.5

23.0

33.7

30.5

44.5

(F) 1.5

33.0

48.5

42.5

62.0

(F) 1.5

46.0

67.5

57.0

83.0

(F) 1.5

61.0

89.5

73.5

105.0

(F) 2.0

78.5

115.0

105.0

155.0

(F) 2.0

115.0

165.0

145.0

215.0

(F) 2.0

160.0

230.0

195.0

290.0

(F) 2.0

210.0

310.0

M24

M27

M30

M33

5/16

18 UNC

2.5

3.6

3/8

16 UNC

4.5

6.6

7/16

14 UNC

7.2

10.5

1/2

13 UNC

10.5

15.0

9/16

12 UNC

15.0

22.0

5/8

11 UNC

20.5

30.0

3/4

10 UNC

36.5

53.5

7/8

9 UNC

56.5

82.5

8 UNC

88.5

130.0

Note: Tighten the bolts according to the above list, unless otherwise specified.

65ZV-2 US 00-15 00 General Information Outline

(lb-ft) Bolt size Type

Nominal dimension

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

19.5

M10

M12

M14

M16

M18 Metric thread

M20

M22

Unified thread

Bolt strength

(F) 1.25

105

150

(F) 1.5

110

160

230

(F) 1.5

165

245

220

320

(F) 1.5

235

350

305

450

(F) 1.5

330

490

410

600

(F) 1.5

440

650

530

760

(F) 2.0

565

830

760

1,120

(F) 2.0

830

1,190

1,050

1,550

(F) 2.0

1,160

1,660

1,410

2,100

(F) 2.0

1,520

2,240

M24

M27

M30

M33

5/16

18 UNC

18.0

3/8

16 UNC

7/16

14 UNC

1/2

13 UNC

105

9/16

12 UNC

110

160

5/8

11 UNC

150

215

3/4

10 UNC

265

385

7/8

9 UNC

410

595

8 UNC

640

940

Note: Tighten the bolts according to the above list, unless otherwise specified.

65ZV-2 US 00-16 00 General Information Outline

Flanged hexagon bolt 1. Bolt type: Metric thread 2. Bolt strength: 8.8 (8T) 3. Thread pitch: Coarse pitch thread (C) (N-m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

0.8

1.25

M10

1.5

M12

1.75

M16

231

M20

2.5

441

M24

765 (kgf-m)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

0.8

0.7

1.2

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

23.5

M20

2.5

45.0

M24

78.0 (lb-ft)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

0.8

5.0

8.6

8.8 (8T)

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

169.2

M20

2.5

324.0

M24

561.6

65ZV-2 US 00-17 00 General Information Outline

Hose band tightening torque Low pressure hose (heat resisting hose)

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

Inner dia. (mm) Outer dia. (mm) 6.3

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

Low pressure hose Inner dia. (mm) Outer dia. (mm) 6

16.5

18.5

20.5

22.0

24.5

26.0

29.0

30.5

32.0

34.0

39.5

41.5

46.0

48.0

54.0

70.5

73.0

69002-02700 69002-03100

69002-02300 69002-02700

69002-03100

69002-03800

69002-04400

69002-05200 69002-05700 69002-07600

To connect the hose to the pipe, tighten the hose band at the following position:

Fix the band avoiding the beading.

2~3 mm (1/8 in) Pipe

Hose Hose band

K50V200002

65ZV-2 US 00-18 00 General Information Outline

Liquid gasket and screw lock agent To reassemble the disassembled parts, be sure to use the specified liquid gasket or screw lock agent or the equivalent according to the following lists:

Liquid gasket

Screw lock agent

Code

Manufacturer

Product name

AA01

Loctite®

Plastic Gasket 568

AA02

Loctite®

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

Loctite® 262

AB01

Loctite

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

Cautions regarding parts removal If a screw or shaft to be removed has been locked by one of the above agents, remove the screw or shaft using a general tool, such as a wrench or puller. If it is difficult to remove the screw or shaft, heat the bolt to soften the agent (200~250°C) using a soldering iron or gas torch.

Caution If there is a seal near the screw or shaft to be removed, carefully use the heating method for removal, to avoid damage to the seal. If heat has been used to remove the bolt a new bolt should be used during reassembly.

Cautions regarding reassembly To reassemble a screw Completely remove the hardened lock agent from the screw and the threaded hole before reassembling the screw. Note A piece of hardened lock agent may be peeled off and remain in the component. The remaining piece may cause malfunction during fastener installation.

To bond a plane or to fit a shaft Remove the hardened lock agent using a wire brush or the like, and polish the surface using sand paper. Use of a Loctite® primer like Locquic® Primer T prepares metal surface of the threads and speeds curing time. Antiseize Agent Code

Manufacturer

AC01

Loctite®

Product name Loctite® 767 (Paste or spray)

65ZV-2 US 00-19 00 General Information Outline

Screw lock agent application procedure

How to wind a seal tape

Through-hole Apply screw lock agent one or two lines on the male threads.

Seal tape Screw lock agent Leave 1~2 screw

65ZV00004a

65ZV00002

As the screw is tightened by turning clockwise, seal tape must be wound up clockwise direction as shown above. If not, the tape will be loosened or removed while tightening the screw, resulting in oil leakage. To avoid a piece of seal tape left in the circuit, leave 1 or 2 screws from the end of the thread and start threading it clockwise. Slightly stretch the tape when cutting it out, and press to fit the tape onto the screw thread.

65ZV-2 US 00-20 00 General Information Outline

Cautions regarding welding repair service If welding is needed to repair the chassis, observe the following precautions to protect the hydraulic cylinders, hydraulic units, gear sets, and electrical units from possible damage.

Cautions 1. Turn the starter switch OFF. 2. Remove the battery terminals both positive and negative sides from the battery.

5. To ground the welder, check that the electric current will not flow through the cylinders. Cylinder head covers for some models have a low conductive metal that will cause spark if the welding current flows. The spark may damage the cylinder rod.

3. Disconnect the connector for MCU (machine controller), ECM (engine controller) and air conditioner. 4. Ground the welder near the section to be welded. Example 1

Section to be welded Do not ground this section. Electric current may flow through the cylinders. Ground this section. (correct grounding)

35C00002

Example 2

Do not ground this section. Electric current may flow through the cylinders.

Section to be welded

Ground this section. (correct grounding)

35C00006

65ZV-2 US 00-21 00 General Information Outline 6. The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes. Be sure to mask these units and parts before welding.

Hydraulic cylinder

Heat-resistant cloth Section to be welded

Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

35A00005

Plated section (Mask this section.)

(c) Hydraulic hoses, nylon tubes, or harnesses are easily damaged by the heat during welding. To protect them from the heat, remove them from the section to be welded to make enough clearance.

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.) 35C00003

(a) Plated section Cover the plated sections with heat-resistant cloth, such as glass wool or canvas. Note The weld spattered on the plated sections causes corrosion.

1m or more

Scrap material, etc.

Section to be welded

1m or more 35C00004

(b) Cover the hydraulic units, electrical units, harnesses, hydraulic hoses, nylon tubes, etc. with heat-resistant cloth (glass wool or canvas) or scrap material to protect them from spatter.

65ZV-2 US 00-22 00 General Information

MEMO

65ZV-2 US 03-1 03 Measurement for Performance Check

03 Measurement for Performance Check Cautions on Safety .................................................. 03-2 Standard Measurement Values for Performance Check ........................................................................... 03-3

65ZV-2 US 03-2 03 Measurement for Performance Check Cautions on Safety

Cautions on Safety WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service man. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine

WARNING Operation under the boom or the bucket may lead to severe accidents. Make sure to apply the safety lock of the boom and the bucket control lever provided in the cab, remove the starter key, and attach a "DO NOT OPERATE!" tag to the cab.

CAUTION Be careful not to be burnt by bursting high pressure oil. Release the pressure remaining inside the circuit and open the cap of the hydraulic tank before removing the plug from the pressure measurement port so that the internal pressure of the hydraulic tank is released and burst of the high pressure oil can be prevented.

WARNING Entering the articulation area of the machine body while the engine is running may cause severe accidents. Make sure to stop the engine, pull out the starter key, and attach a "DO NOT OPERATE!" tag to the cab before entering the articulation area.

CAUTION Touching the fan or the V belt of the engine or the hot area while the engine is running may cause severe accidents. Make sure to stop the engine before opening the engine room access panel.

65ZV-2 US 03-3 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Standard Measurement Values for Performance Check Measurement conditions Temperature of torque converter oil: 50~80°C (120~180°F) Temperature of hydraulic oil: 50~80°C (120~180°F) Temperature of engine coolant: 50~80°C (120~180°F) Standard measurement values for performance check

Item Measurement item

Engine

System

Engine speed (min-1) (rpm) (S/N 5001~5100)

Minimum no-load speed, Low Idle (LI)

800±50

Maximum no-load speed, High Idle (HI)

2,450±50

Maximum speed in torque converter stall mode

2,280±100

2,170±100

Maximum speed in multiple control valve relief mode

2,310±100

2,290±100

Maximum speed in torque converter stall plus multiple control valve relief mode

1,805 +150 - 100

1,545 +150 - 100

Transmission

Engine

Minimum no-load speed, Low Idle (LI)

Engine speed (min-1) (rpm) (S/N 5101~)

800±50

Maximum no-load speed, High Idle (HI)

2,410±50

2,100±50

Maximum speed in torque converter stall mode

2,280±100

2,100±100

Maximum speed in multiple control valve relief mode

2,310±100

Maximum speed in torque converter stall plus multiple control valve relief mode

1,805 +150 - 100

1,545 +150 - 100

Idling (LI)

Clutch pressure MPa (kgf/cm2) (psi)

Engine speed

Clutch time lag (sec)

NeutralForward 1st speed (engine speed: 1,500 min-1 (rpm))

Maximum (HI)

Remarks

Fuel efficient mode

Normal

1.5 (15) (213) or more 1.8~2.1 (18~21) (256~299) 0.3±0.1

Before wheel move

65ZV-2 US 03-4 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Standard measurement values for performance check

Item Measurement item

System

Cylinder drift Boom cylinder (when boom and bucket are horizontal and with no load) Bucket cylinder (mm/min) (in/min)

Boom rising time (no load) (sec)

Hydraulic pressure

Full steering time (sec)

Relief valve setting pressure MPa (kgf/cm2) (psi)

Fan maximum revolution (HI) min-1 (rpm)

Fan minimum revolution (LI) min-1 (rpm)

3 (1/8) or less

4 (5/32) or less Idling (LI)

Engine speed

Remarks

17.9±3.0 -1

1,500 min (rpm)

8.9±1.0

Maximum (HI)

5.8±0.5

Idling (LI)

3.4±0.5 -1

1,500 min (rpm)

2.3±0.3

Maximum (HI)

2.3±0.3

Loading line main relief pressure (HI)

20.6±0.5 (210±5) (2,986±71)

Loading line overload relief pressure (LI)

23.5±0.5 (240±5) (3,413±71)

Steering line main relief pressure (HI)

20.6±0.5 (210±5) (2,986±71)

Steering line overload relief pressure (LI)

23.5±0.5 (240±5) (3,413±71)

Run engine at lowest possible speed while setting

Pilot line reducing pressure (LI)

3.5 (36) (512)

Run engine at lowest possible speed while setting

Engine water temperature <80ºC (180ºF) T/C oil temperature <110ºC (230ºF) Hydraulic oil temperature <90ºC (195ºF)

1,120 +75 - 200

Engine water temperature >95ºC (205ºF) T/C oil temperature >115ºC (240ºF) Hydraulic oil temperature >95ºC (205ºF)

1,600 +100 - 50

Engine water temperature <60ºC (140ºF) Engine idle revolution

690 +50 - 200

Run engine at lowest possible speed while setting

65ZV-2 US 03-5 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Item Measurement item

System

Shift lever position

2nd speed reverse

Engine speed

Maximum (HI)

Shift lever position

3rd speed reverse

Performance of service brake

Performance of parking brake

Brake

Slowly increase the engine speed, and check that the machine does not move at the maximum engine speed.

The same as above Engine speed

Brake line setting pressure MPa (kgf/cm2) (psi)

Standard measurement values for performance check

Maximum (HI)

Off (Cut-out)

11.8±0.5 (120±5) (1,706±71)

On (Cut-in)

6.9±1.0 (70±10) (995±142)

Unloader valve setting pressure

Low-pressure alarm switch setting pressure (For brake accumulator circuit) The time from the low-pressure alarm is turned off till the unloading valve cuts off pressure

Remarks

Brake pedal fully depressed and held down during test.

Before brake check, be sure to disconnect the cable connector of parking brake solenoid valve.

4.1±0.5 (42±5) (594±71)

Accumulator charge time (sec)

Engine speed (LI)

Number of brake pedal applications

Run engine 1 minute high idle, then stop the engine. (Turn key switch "ON" with engine off.) Step on the brake pedal and release, and check the number of times until the low-pressure alarm is turned on.

at least 7 times

Repeat stepping on the brake pedal as follows: On: 5 sec. Off: 5 sec.

Declutch engagement (cm) (in)

Engine: Maximum speed/ Declutch pedal: Quick release (Distance the loader rolls back before moving forward.)

15 (6) or less

1/5 slope (approx. 11º), unladen, 1st speed

Note These are the standard measurement values for the machines at the time when delivered from the factory.

2.6

65ZV-2 US 03-6 03 Measurement for Performance Check

MEMO

65ZV-2 US 12-1 12 Function & Structure Chassis Group

12 Function & Structure Chassis Group Front Chassis .......................................................... 12-2 Rear Chassis........................................................... 12-5 Center Pin ............................................................... 12-8

65ZV-2 US 12-2 12 Function & Structure Chassis Group Front Chassis

Front Chassis Loading linkage

5 9

65ZV12001

1. Bucket 2. Link 3. Lever 4. Boom 5. Bucket cylinder 6. Boom cylinder 7. Dump stopper surface 8. Roll-back stopper surface 9. Lever stopper surface 10. Bucket stop plate (Design differs by manufacturer of the attachment)

65ZV-2 US 12-3 12 Function & Structure Chassis Group Front Chassis

Even contact both sides

200 mm (7.9 in)

(Hinge pin height at bucket on ground)

Typical bucket roll-back stopper adjustment (Contact attachment supplier for details on non-standard attachments)

3770 mm (12’ 5 1/4")

A=5 2 mm (0.2 0.08 in) Typical bucket dump stopper clearance (Contact attachment supplier for details on non-standard attachments) To increase clearance increase height of #9 To reduce clearance decrease height of #9 65V2E12001

65ZV-2 US 12-4 12 Function & Structure Chassis Group Front Chassis

Loading linkage pin mm (in) 1. Bucket - Boom

2. Boom - Lever

3. Boom - Boom cylinder

4. Front chassis - Boom

5. Bucket - Link

6. Lever - Link

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

8 4

11 10

65ZV12003

65ZV-2 US 12-5 12 Function & Structure Chassis Group Rear Chassis

Rear Chassis Fuel tank (S/N 5001~5128) 3 3 1 7

5 7 6

View A

EMPTY

212 L (56 gal)

FULL

184 L (49 gal)

110 L (29 gal)

31 mm (1.22 in)

View B 65V2E12002

1. Fuel tank 2. Fuel level sensor 3. Fuel tank filler assembly 4. Drain valve 5. Inspection hole cover 6. Suction pipe 7. Fuel return pipe

65ZV-2 US 12-6 12 Function & Structure Chassis Group Rear Chassis

Fuel tank (S/N 5129~)

(S/N 5401~)

1. Fuel tank 2. Fuel level sensor 3. Fuel tank filler assembly 4. Drain valve (S/N 5401~ square socket head) 5. Inspection hole cover 6. Suction pipe 7. Fuel return pipe 8. Filter

65ZV-2 US 12-7 12 Function & Structure Chassis Group Rear Chassis

Floor board mount

Viscous mount

Floor board

3 4 80ZVE12007

1. Floor board 2. Viscous mount 6

The floor board is installed on the rear chassis by the rubber cushion. The instrument panel, control box, operator’s seat and the air conditioner unit are on the floor board.

70ZV12007

The floor board is supported by a viscous mount in four positions so that vibrations, impacts and sounds generated in the chassis are not transmitted to the inside of cabin.

S/N 5001~5050 (Bergstrom A/C unit)

S/N 5051~ (DENSO A/C unit) K70T2U12001

1. Stud 2. Cushion rubber 3. Case 4. Cap 5. Damping plate 6. Plain washer 7. Head bolt 8. Silicon oil 9. Plug

65ZV-2 US 12-8 12 Function & Structure Chassis Group Center Pin

Center Pin Upper center pin

Lower center pin 3 4 1 4

10,11 3 2

5 6

Front chassis

Front chassis 7

Rear chassis

Rear chassis 2

9,11

1 Lower

Upper 65ZV12008

65ZV12011

Upper

Lower

1. Center pin 2. Cover 3. Bearing cover 4. Sleeve 5. Shim 6. Bearing assembly 7. Dust seal 8. Bushing 9. Bolt 10. Bolt 11. Washer

1. Center pin 2. Dust seal 3. Bolt 4. Plate

65ZV-2 US 12-9 12 Function & Structure Chassis Group Center Pin

Dust seal

Center pin

Dust seal position 70ZV12008

When installing the dust seal, check that the lip faces toward the outside. If the lip faces toward the outside, the dust will not be drawn through the seal.

65ZV-2 US 12-10 12 Function & Structure Chassis Group

MEMO

65ZV-2 US 13-1 13 Check & Adjustment Chassis Group

13 Check & Adjustment Chassis Group Linkage Pin ............................................................. 13-2 Center Pin ............................................................... 13-4

65ZV-2 US 13-2 13 Check & Adjustment Chassis Group Linkage Pin

Linkage Pin WARNING

CAUTION

Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting adjustment work, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Remove the starter key, and hang a "DO NOT OPERATE!" tag on the steering wheel. - Block the tires with chocks to prevent the tires from moving.

Unexpectedly dropped parts may cause an accident resulting in injury. - Before liner insertion, be sure to lift the cylinder using a crane to prevent the cylinder from unexpectedly dropping during liner insertion. - Wear protective clothes like work gloves and steel toed shoes.

Liner

3 4

65ZV12005

Adjustment portion

Liner hole diameter mm (in)

61 (2.40)

101 (3.98)

71 (2.80)

81 (3.19)

Adjustment unnecessary

41 (1.61)

65ZV-2 US 13-3 13 Check & Adjustment Chassis Group Linkage Pin

Adjustment

95ZV12005

Adjust the clearance (*) to 1.2 mm or less between the bosses using liner of 1 mm thickness. For the steering cylinder, be sure to adjust the clearance on the rear chassis side first and then on the front chassis side while checking that the cylinder is not inclined.

65ZV-2 US 13-4 13 Check & Adjustment Chassis Group Center Pin

Center Pin Adjusting shim

1 4

10,11 3 5 6 Front chassis 7 Rear chassis 2 Upper

9,11

65ZV12008

The clearance between the front chassis and bearing cover (3) is 0.75±0.5 mm (0.03±0.02 in) before shim adjustment. Add shims (5) so that the clearance is 0.1±0.05 mm (0.004±0.002 in).

65ZV-2 US 22-1 22 Function & Structure Power Group

22 Function & Structure Power Group Power Line .............................................................. 22-2 Engine / Transmission............................................. 22-3 Radiator................................................................... 22-4 Propeller Shaft......................................................... 22-6 Axle Assembly......................................................... 22-9 Axle Support............................................................ 22-10 Differential Gear ...................................................... 22-12

65ZV-2 US 22-2 22 Function & Structure Power Group Power Line

Power Line

65V2E22001

1. Engine 2. Torque converter and transmission 3. Radiator 4. 2nd propeller shaft 5. 3rd propeller shaft 6. Front axle differential gear 7. Rear axle differential gear 8. Parking brake 9. Air cleaner 10. Muffler 11. Hydraulic oil cooler 12. Torque converter oil cooler 13. Air charge cooler 14. Fan motor

The power output from the engine is transmitted to the transmission through the torque converter (combined with the transmission). The speed and direction are changed according to the engagement of the transmission clutches. The power is then transmitted through the second and third propeller shafts to the differential gears of front and rear axles. Finally the power is transmitted through the axles to the planetary gears, and tires to move the machine. On the back side of the engine, there are a radiator and a torque converter oil cooler. The radiator incorporates engine coolant, air charge cooler and an external air type hydraulic oil cooler. The torque converter oil cooler is separately installed behind the engine. On the second propeller shaft side of the transmission, a parking brake is installed.

65ZV-2 US 22-3 22 Function & Structure Power Group Engine / Transmission

Engine / Transmission Engine / transmission mount

A B

A E/G flywheel housing

4 (12 pcs) T/C

3 1

1 5 (8 pcs) Engine Flexible plate

Transmission

2 A-A

2 B-B

E/G & T/C connection 65V2E22002

1. Bushing-Elastic 2. Washer 3. Bracket 4. Flange bolt 5. Flange bolt

Bolts are used to connect the engine flywheel housing to the transmission housing, and a flexible plate is used to transmit the engine power to the transmission. Therefore no thrust load is placed on the engine flywheel or crankshaft. Elastic cushions are used to mount the engine and the transmission on the chassis.

65ZV-2 US 22-4 22 Function & Structure Power Group Radiator

Radiator

Hydraulic oil cooler IN

Charge air cooler IN

Coolant IN

Hydraulic oil cooler OUT

B 2

1 4

T/C oil cooler IN

T/C oil cooler OUT

Charge air cooler OUT

Coolant OUT

K65V2U22001

1. Radiator assembly 2. Stay (Bracket) 3. Air charge cooler 4. Hydraulic oil cooler 5. T/C oil cooler

The radiator incorporates the engine coolant, cooling fin, air charge cooler, and an external air type hydraulic oil cooler. For the engine coolant, air charge cooler and hydraulic oil, the air-cooling system is used. For the torque converter oil, the water-cooling system is used. The air charge cooler is required to meet engine emission regulations.

65ZV-2 US 22-5 22 Function & Structure Power Group Radiator

Radiator mount 7 6

9 8 A-Detail

B-Detail 70V2E22004

1. — 2. — 3. — 4. — 5. — 6. Bushing-Rubber 7. Washer 8. Bushing-Rubber 9. Bolt

Capacity in radiator: 9.9 L (2.6 gal) Cooling water 3.6 L (0.95 gal) Hydraulic oil Torque converter oil 1.6 L (0.4 gal) Dry weight

130 kg (285 lbs)

65ZV-2 US 22-6 22 Function & Structure Power Group Propeller Shaft

Propeller Shaft

65V2E22004

1. 2nd propeller shaft 2. 3rd propeller shaft (fixed type) 3. Pillow block 4. Slip joint

The engine power is transmitted to the torque converter and the transmission, and is then transmitted to the second and the third propeller shafts to the front and the rear axle. For the second propeller shaft, the universal joint and slip joint type spline shaft are used for smooth power transmission at any steering angle or change in propeller shaft length. The third propeller shaft is the fixed type with universal joints.

65ZV-2 US 22-7 22 Function & Structure Power Group Propeller Shaft

Second propeller shaft assembly Front differential – Transmission

1 Z

2 b

Grease nipple installation angle (a, b, c, d)

View Z

4 Every 12000 hours greasing

Every 2000 hours greasing

Every 12000 hours greasing

65V2E22005

1. Journal spider assembly 2. Sleeve yoke assembly 3. Propeller shaft assembly 4. Pillow block

65ZV-2 US 22-8 22 Function & Structure Power Group Propeller Shaft

Third propeller shaft assembly Transmission – Rear differential

Grease nipple installation angle

A 45

A View B

View A

1 Every 12000 hours greasing

Every 12000 hours greasing 65V2E22006

1. Journal spider assembly 2. Coupling yoke

65ZV-2 US 22-9 22 Function & Structure Power Group Axle Assembly

Axle Assembly 28 27

18 19

14 14

21 8 22

9 21

7 26 14 20 14

17 15

15 10 2 4 15

28 27

13 23

5 24 25

1. Differential assembly 2. Axle housing assembly 3. Internal gear 4. Spider (planetary carrier) 5. Axle shaft 6. Piston 7. Sun gear 8. Planetary gear 9. Separation disc 10. Planetary pin

11. Friction disc 12. Taper roller bearing 13. Taper roller bearing 14. Straight pin 15. Spring pin 16. Plane washer 17. Shim 18. O-ring (inner) 19. O-ring (outer) 20. Brake backing plate

21. Wear ring 22. Needle cage 23. Oil seal 24. Plug 25. Bolt 26. Bolt 27. Spring pin 28. Plug 29. Vent to hydraulic tank

65ZV22014

65ZV-2 US 22-10 22 Function & Structure Power Group Axle Support

Axle Support

A 2

1 1 9 Front axle support

4 5 6 Rear axle housing

Front Grease pipe connection port (PT 1/8) 3

8 Rear axle support

7 5

View A-A

A Large chamfer

Large chamfer

Small chamfer

5 7 4 #7 Details (Front side)

1. Axle support (front) 2. Axle support (rear) 3. Plate 4. Lip seal 5. Lip seal 6. Wear ring 7. Bushing 8. Elbow 9. Plate

Small chamfer

7 #7 Details (Rear side)

65V2E22007

65ZV-2 US 22-11 22 Function & Structure Power Group Axle Support

1 8

Rear axle housing

7 9

6 3 6 Front

7 5 2

65V2E22008

1. Axle support (front) 2. Axle support (rear) 3. Plate 4. Lip seal 5. Lip seal 6. Wear ring 7. Bushing 8. Elbow 9. Plate

65ZV-2 US 22-12 22 Function & Structure Power Group Differential Gear

Differential Gear Front differential gear (S/N 5001~5100)

2 3 6

5 7 9

12 11

13 16

17 15

65ZV22017

1. Flange 2. Oil seal 3. Cage 4. Shim 5. Taper roller bearing 6. Collar 7. Drive pinion 8. Carrier 9. Pilot bearing

10. Nut 11. Taper roller bearing 12. Adjusting nut 13. Side gear 14. Thrust washer (side gear) 15. Differential pinion 16. Thrust washer (pinion gear) 17. Ring gear 18. Spider (cross shaft)

65ZV-2 US 22-13 22 Function & Structure Power Group Differential Gear Front differential gear (S/N 5101~)

2 3

6 8 9

11 12

16 18

K65V2U22002

1. Flange 2. Oil seal 3. Cage 4. Shim 5. Taper roller bearing 6. Collar 7. Drive pinion 8. Carrier 9. Pilot bearing 10. Nut

11. Taper roller bearing 12. Adjusting nut 13. Side gear 14. Thrust washer (side gear) 15. Differential pinion 16. Thrust washer (pinion gear) 17. Ring gear 18. Spider (cross shaft) 19. Snap ring

65ZV-2 US 22-14 22 Function & Structure Power Group Differential Gear Rear differential gear (S/N 5001~5100)

3 2

7 8

12 11

65V2E22009

1. Flange 2. Oil seal 3. Cage 4. Shim 5. Taper roller bearing 6. Collar 7. Drive pinion 8. Carrier 9. Pilot bearing

10. Nut 11. Taper roller bearing 12. Adjusting nut 13. Side gear 14. Thrust washer (side gear) 15. Differential pinion 16. Thrust washer (pinion gear) 17. Ring gear 18. Spider (cross shaft)

65ZV-2 US 22-15 22 Function & Structure Power Group Differential Gear Rear differential gear (S/N 5101~)

2 3

4 7

5 6

8 9

19 11 12 13

15 K65V2U22003

1. Flange 2. Oil seal 3. Cage 4. Shim 5. Taper roller bearing 6. Collar 7. Drive pinion 8. Carrier 9. Pilot bearing

10. Nut 11. Taper roller bearing 12. Adjusting nut 13. Side gear 14. Thrust washer (side gear) 15. Differential pinion 16. Thrust washer (pinion gear) 17. Ring gear 18. Spider (cross shaft) 19. Snap ring

65ZV-2 US 22-16 22 Function & Structure Power Group Differential Gear

Function of T.P.D

Contact between pinion and side gear

The differential gear used for the machine is the torque proportioning type. Compared with the conventional differential, the torque proportioning differential (T.P.D.) can reduce tire slippage on sandy or muddy ground.

T.P.D.

Conventional differential

Difference in gear shapes

This prevents some of the reduction in rim - pull and tire wear caused by tire slippage.

Shaft center of side gear 95ZV22018

Conventional differential

Conventional differential There is little change in distance from the shaft center of the side gear. T.P.D. The contact point varies as the gear rotates. The distance between the contact point and the shaft center of the side gear also varies in the range of R1~R2.

T.P.D.

95ZV22014

Conventional differential Standard bevel gear T.P.D. Special bevel gear The gear width is 35~50% longer than the conventional differential.

65ZV-2 US 22-17 22 Function & Structure Power Group Differential Gear

Operation of T.P.D Rotational direction

Pinion

Pinion Side gear

R1 [A] The surface resistance values of the right and left wheels are identical to each other.

[B] The surface resistance of the left wheel is low due to sandy ground or the like.

[C] The surface resistance of the right wheel is low.

95ZV22015

The function of the T.P.D. is as follows: If the surface resistance values of the right and left wheels differ from each other, engagement position of the pinion gear with the side gears will be automatically shifted to transmit different torque to the right and left wheels. Different torque in right and left wheels prevents the tires from slipping. The number of pinion gear teeth is an odd number, and the pinion gear operate as follows. 1. When the traction of the right and left wheels are identical to each other, the pinion and side gears will be engaged as shown in figure [A]. In this case, the torque arms of both side gears are identical to each other (R1 = R2). As a result, identical driving force will be applied to both the right and left wheels. 2. If the left wheel loses traction the engagement position between the pinion and side gears will be shifted as shown in figure [B] to quickly rotate (spin) the left wheel. As a result, the torque arms of the both side gears differ from each other (R1> R2), and the driving force of the left wheel is small. As a result, tire slipping can be reduced. When the driving force of the left wheel is reduced

(slipping occurs), the driving force of the right wheel will be increased to limit the reduction in the total amount of the driving force. Assuming that the driving torque of the right wheel is TR, and that of the left wheel is TL, the relation between TR and TL can be expressed as follows: R TR ------ = ------1 TL R2 The value obtained from the above formula is referred to as the bias ratio. The limit of the bias ratio is 1.4. In other words, until the difference in the surface resistance between the right and left tires is increased to 40%, the pinion gear will be properly engaged with the shifted side gears, and driving force will be properly applied to both the side gears to prevent the tires from slipping. 3. If the surface resistance of the right wheel is reduced, the engagement position between the pinion and side gears will be shifted as shown in figure [C] above. In this case, the right and left sides are reversed compared with the above description.

65ZV-2 US 22-18 22 Function & Structure Power Group Differential Gear

Limited Slip Differential (option) Note 1. Clutch assembly (2) is built with three plates as a unit. Do not change this combination. 2. When installing clutch assembly (2), make sure of the direction of plates (surfaces with lining and surface without lining).

Differential assembly

With lining Without lining

Differential cage

Side gear

4 3

2 5

Bolt (5) : 127 N-m (13.0 kgf-m) (94 lb-ft) : Screw lock agent (Loctite 262®) application

Limited Slip Differential

3 1

2 2 3 1

1. Differential cage 2. Clutch assembly 3. Side gear 4. Pin 5. Bolt K65V22001

65ZV-2 US 22-19 22 Function & Structure Power Group Differential Gear Front differential gear

2 3

5 6

7 8 9 20

11 12

16 18

K65V2U22004

1. Flange 2. Oil seal 3. Cage 4. Shim 5. Taper roller bearing 6. Collar 7. Drive pinion 8. Carrier 9. Pilot bearing 10. Nut

11. Taper roller bearing 12. Adjusting nut 13. Side gear 14. Clutch assembly 15. Differential pinion 16. Thrust washer (pinion gear) 17. Ring gear 18. Spider (cross shaft) 19. Snap ring 20. Pin

65ZV-2 US 22-20 22 Function & Structure Power Group Differential Gear Rear differential gear

10 2 3

4 7

5 6

8 9 20

11 12

15 K65V2U22005

1. Flange 2. Oil seal 3. Cage 4. Shim 5. Taper roller bearing 6. Collar 7. Drive pinion 8. Carrier 9. Pilot bearing 10. Nut

11. Taper roller bearing 12. Adjusting nut 13. Side gear 14. Clutch assembly 15. Differential pinion 16. Thrust washer (pinion gear) 17. Ring gear 18. Spider (cross shaft) 19. Snap ring 20. Pin

65ZV-2 US 22-21 22 Function & Structure Power Group Differential Gear

LSD function

LSD operation Performance comparison between LSD and TPD Differential pinion

LSD differential point 0.48 (bias ratio 2.1)

Torque

LSD clutch assembly Differential cage

ir e et n O

0.1

Axle shaft

ins sp

e th

e ng ra

s in spin

ope LSD

range

TPD differential point 0.71 (bias ratio 1.4)

e rang the

ting o p e ra TP D range

tire One 0.2 0.3 0.4 0.5 0.6 0.7 0.8 Friction ratio between right and left tires

Side gear Side gear moves to the left and pushes LSD clutch.

rating

0.48

LSD TPD

0.9

Torque is transferred to the right and left tires evenly until the friction ratio between the right and left tires comes to 0.48:1 (=1:2.1). The result is that the LSD adds tractive effort.

A - Detail 70V2E22011

LSD (Limited-Slip Differential) is installed between the side gear and the differential cage in TPD (Torque Proportioning Differential), and increases tractive effort. If the surface traction of the right and left tires differ from each other during operation, LSD clutch engages and prevents traction loss. The performance of LSD is shown by using the bias ratio. The bias ratio is the ratio between the driving force of the right and left tires while the differential pinion is turned. When the bias ratio is larger, it is easier to gain traction on the ground surface with less resistance.

K65ZV22011

The following shows operation for the left tire. A rotating driving force is transmitted from the differential cage via spider (cross shaft) to the differential pinion and the side gear. When the ground surface resistance for the left tire lessens, the tapered interface between the differential pinion and the left side gear induces a side force. It pushes the left side gear to the left resulting in frictional engagement with the differential cage, thus impeding free left side gear rotation and gaining traction.

65ZV-2 US 22-22 22 Function & Structure Power Group

MEMO

65ZV-2 US 23-1 23 Check & Adjustment Power Group

23 Check & Adjustment Power Group Engine ..................................................................... 23-2 Propeller Shaft......................................................... 23-3

65ZV-2 US 23-2 23 Check & Adjustment Power Group Engine

Engine Measuring engine oil pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men. - Prohibit any person from walking into dangerous areas. - Near articulation area of the machine - Under the machine - Around the engine - In front of or behind the machine

Measurement instrument - Pressure gauge

Install position 1. Location A 2. Measuring port: M10x1.00 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (150 psi)

Standard measurement value

CAUTION Do not touch the fan or V-belt of the engine or hightemperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is stopped. Use a photo tachometer when checking engine revolution.

Engine speed

Service standard

800 min-1

150 kPa (1.5 kgf/cm2) (21 psi)

2,000 min-1

450 kPa (4.6 kgf/cm2) (65 psi)

[Engine coolant temperature 50ºC (120ºF)]

Measuring engine speed Measurement instrument A

- Tachometer

Standard measurement value Low idle (min-1): 800±50 High idle (min-1): 2,450±50 (S/N 5001~5100) 2,410±50 (S/N 5101~) A 65V2E23001

65ZV-2 US 23-3 23 Check & Adjustment Power Group Propeller Shaft

Propeller Shaft Propeller shaft phase

Third propeller shaft

Second propeller shaft

Front differential

Transmission

Rear differential

95ZV22007

Adjust the yokes of the second and third propeller shafts to the same direction (phase). - The propeller shaft attaches to the transmission shaft. The shaft from the front differential to the rear differential is referred to as the propeller shaft. The propeller shaft articulates as the machine turns. When the propeller shaft is articulated due to machine steering, differences in the yoke phases (directions) will cause unbalance between the transmission torque and the reaction force. As a result, the propeller shaft will extremely vibrate, and the service life of the shaft will be shortened.

Second propeller shaft alignment

Top view Differential side

(C)

(B)

(A)

Transmission side

Side view 95ZV22008

- As misalignment may produce an abnormal noise, be sure to align points (A), (B), and (C) of the yokes when reassembling the propeller shaft.

65ZV-2 US 23-4 23 Check & Adjustment Power Group Propeller Shaft

Tightening torque 2nd propeller shaft

Pillow block (Center bearing)

3rd propeller shaft

Rear diff. Front diff.

4 7

3 6

Front diff. side

5 65V2E23002

IMPORTANT Never reuse universal joint or driveline bolts or locks. Always use new bolts and secure with loctite® 262 and primer. : 1, 2, 3. 79.9 N-m (8.15 kgf-m) (59 lb-ft) 4. 230 N-m (23.5 kgf-m) (170 lb-ft) 5. 77 N-m (7.9 kgf-m) (57 lb-ft) 6. 304 N-m (31 kgf-m) (225 lb-ft) 7. 18 N-m (1.8 kgf-m) (13 lb-ft)

#1, 2, 3, 4: Screw lock agent (Loctite® 262)

65ZV-2 US 32-1 32 Function & Structure Torque Converter and Transmission Group

32 Function & Structure Torque Converter and Transmission Group Torque Converter .................................................... 32-2 Torque Converter Gear Pump ................................. 32-3 Transmission ........................................................... 32-4 Clutch Pack ............................................................. 32-10 Power Flow Path in the Transmission ..................... 32-13 Hydraulic System Diagram...................................... 32-18 Hydraulic Circuit Diagram........................................ 32-19 Oil Flow ................................................................... 32-20 T/C and T/M Oil Circulation ..................................... 32-21 Control Valve ........................................................... 32-23 Modulation Mechanism ........................................... 32-25 Accumulator ............................................................ 32-29 Clutch Solenoid Valve ............................................. 32-30

65ZV-2 US 32-2 32 Function & Structure Torque Converter and Transmission Group Torque Converter

Torque Converter Torque multiplication

Output

Torque ratio (t)

Input

S P

95ZV32002

0.5 Speed ratio (e)

1.0

95ZV32003

Torque converter structure The torque converter is between the engine and transmission, and consists of three impellers as shown in the figure. The three impellers are pump (P), turbine (T), and stator (S) impellers.

If the engine speed/pump impeller speed stays the same but the turbine impeller speed is reduced due to the transmission load-output torque is increased. This is "torque multiplication". Heat is also generated. Turbine impeller speed (min –1 ) (rpm) Speed ratio(e)= -----------------------------------------------------------------------------------------------Pump impeller speed (min – 1 ) (rpm)

Power flow path The pump is connected to the engine flywheel, and rotates together with the engine. The turbine is connected to the torque converter output shaft to transmit the power to the transmission. The stator is fixed to the torque converter case. The area of the impellers is filled with oil. When the engine is started, the pump impeller rotates, therefore the oil will circulate to rotate the turbine impeller (circulation order: pumpturbinestatorpump). Oil is redirected by the fixed stator impeller back to the pump impeller. When the turbine impeller rotates, the power will be transmitted to the output shaft.

65ZV-2 US 32-3 32 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump

Torque Converter Gear Pump Pump specifications

70ZV32004

1. Front body 2. Rear body 3. Drive gear 4. Driven gear 5. Side plate 6. Metal bushing 7. O-ring 8. Oil seal 9. Pin 10. Bolt 11. Snap ring

Theoretical discharge volume

38.5 cc/rev

Max. discharge pressure

2.9 MPa (30 kgf/cm2) (427 psi)

Max. pump speed

3,000 min-1 (rpm)

Actual discharge pump rev. 1,800 min-1(rpm) oil temp. at 50°C (discharge pressure 2.9 MPa (30 kgf/cm2)(427 psi)

60 L/min (15.85 gal/min.)

Oil viscosity

Engine oil 10W (CD)

65ZV-2 US 32-4 32 Function & Structure Torque Converter and Transmission Group Transmission

Transmission Clutch combination Clutch Speed range

Downshift button operation 3

This feature permits quick up and down shifting when in 2nd and Automatic.

It operates from 2nd to 1st, and 1st to 2nd.

F2 F3 F4 N



(Either 1st or 2nd or 3rd)

R1 R2 R3 R4

The transmission is equipped with six clutches: Forward range, reverse, and 1st, 2nd, 3rd and 4th speeds. Combining the clutches as shown in the table here provides four forward speeds, and four reverse speeds for a total of eight speeds. Two clutches must be engaged at the same time to move the machine.

Shift lever position Position of shift lever

Function

Held in 1st speed range for both forward and reverse.

Held in 2nd speed range for both forward and reverse. Downshift button operation.

Held in 3rd speed range for both forward and reverse.

Automatic speed change according to shift map (computer) for 2nd through 4th speeds forward and reverse. Downshift button operation.

Automatic or manual speed change is available depending on the position of the shift lever, as shown in the table. Automatic speed change refers to one where the best speed range is determined by a computer according to the machine speed detected.

65ZV-2 US 32-5 32 Function & Structure Torque Converter and Transmission Group Transmission

Gear train and number of teeth 10

21 32

8 13 37

31 29

24 29

18 50

2 43

Gear arrangement 38

29 57

32 3

65V2E32001

Note Numbers below correspond to page 92-4. No. 8

Gear name PTO drive gear

Number of teeth

No.

Gear name Counter gear B

Number of teeth 43

T/C pump drive gear

Idler

Hydraulic pump drive gear

4th speed clutch gear

Reverse clutch gear

3rd speed clutch gear

Forward clutch gear

Counter gear C

Counter gear A

Counter gear D

2nd speed clutch gear

Counter gear E

1st speed clutch gear

Output shaft gear

65ZV-2 US 32-6 32 Function & Structure Torque Converter and Transmission Group Transmission

Valve location

T/M control valve (3rd / 4th)

T/M control valve (F, R, 1st, 2nd)

Accumulator (2nd clutch)

Accumulator (1st clutch) View A 65V2E32002

65ZV-2 US 32-7 32 Function & Structure Torque Converter and Transmission Group Transmission

Main clutch oil regulator

Outlet regulator

Inlet regulator A-A

B-B

View G Accumulator (2nd clutch)

Accumulator (1st clutch)

C-C

D-D 65V2E32003

65ZV-2 US 32-8 32 Function & Structure Torque Converter and Transmission Group Transmission

Clutch specifications Friction plate Name of clutch

Piston stroke (mm)

Forward clutch

3.0±0.2

Reverse clutch

3.0±0.2

Outer Number of diameter plate (mm)

Inner diameter (mm)

ø173

ø121

Steel plate Outer Thickness (mm) Number of diameter New/Wear limit plate (mm) 8

3.0±0.1 / 2.8

1st speed clutch

2.4±0.2

2nd speed clutch

2.4±0.2

3rd speed clutch

2.4±0.1

4th speed clutch

1.8±0.1

ø158

ø108

2.7±0.1 / 2.5

Inner diameter (mm)

Thickness (mm) New/Wear limit

ø179.5

ø120

2.0±0.08 / 1.8

ø164.5

ø107

2.0±0.08 / 1.8

Note: All friction plates, steel plates are the same for each clutch.

Friction plate: mm (in) For forward, reverse clutch 3 0.1 (0.12 0.004) 2 0.1 (0.08 0.004) 0.5 (0.02) 1 0.15 mm (0.006 in) or more 2

173 0.25 (6.811 0.01)

+0.012 1 +0.3 ) 0 (0.04 0

5.7 0.3 (0.224 0.01)

65V2E32004

1. Plate 2. Facing (paper)

65ZV-2 US 32-9 32 Function & Structure Torque Converter and Transmission Group Transmission For 1st, 2nd, 3rd, 4th speed clutch 2.7 0.1 (0.11 0.004) 1.7 0.1 (0.07 0.004) 0.5 (0.02) 1 0.15 mm (0.006 in) or more 2

158 0.25 (6.220 0.01)

2 0.25 (0.079 0.01)

8 0.3 (0.314 0.01)

65V2E32005

1. Plate 2. Facing (paper)

65ZV-2 US 32-10 32 Function & Structure Torque Converter and Transmission Group Clutch Pack

Clutch Pack Forward and reverse clutch 6

3, 4

F Clutch

1. Clutch drum 2. Clutch piston 3. Friction plate 4. Steel plate 5. Main shaft 6. Forward clutch gear 7. Reverse clutch gear 8. Return spring

R Clutch

65V2E32006

65ZV-2 US 32-11 32 Function & Structure Torque Converter and Transmission Group Clutch Pack

1st and 2nd speed clutch 6

3, 4

26T 33T 43T

1ST

2ND 57T 65V2E32007

1. Clutch drum & counter gear B 2. Clutch piston 3. Friction plate 4. Steel plate 5. Counter shaft A 6. 1st speed clutch gear (Helical type) 7. 2nd speed clutch gear 8. Return spring 9. Residual pressure preventive check valve 10. Counter gear A

65ZV-2 US 32-12 32 Function & Structure Torque Converter and Transmission Group Clutch Pack

3rd and 4th speed clutch

3, 4

23T

37T 38T

3RD

47T

4TH

62T

65V2E32008

1. Clutch drum & counter gear C 2. Clutch piston 3. Friction plate 4. Steel plate 5. Counter shaft B 6. 3rd speed clutch gear 7. 4th speed clutch gear 8. Return spring 9. Residual pressure preventive check valve 10. Counter gear D (Helical type) 11. Counter gear E (Helical type)

65ZV-2 US 32-13 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Power Flow Path in the Transmission Forward 1st speed power flow path 2 F

6 7 1ST

2ND

11 12

13 3RD

4TH

65V2E32009

The power from the torque converter is transmitted to; F-clutch  2. Gear  3. Gear  6. Gear  1st speed clutch  7. Gear  11. Gear  12. Gear  13. Gear then the power is finally transmitted to the output shaft.

65ZV-2 US 32-14 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Forward 2nd speed power flow path

2 F

6 5 1ST

2ND

13 3RD

4TH

65V2E32010

The power from the torque converter is transmitted to; F-clutch  2. Gear  3. Gear  6. Gear  2nd speed clutch  5. Gear  9. Gear  12. Gear  13. Gear then the power is finally transmitted to the output shaft.

65ZV-2 US 32-15 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Forward 3rd speed power flow path

2 F

1ST

2ND

13 3RD

4TH

65V2E32011

The power from the torque converter is transmitted to; F-clutch  2. Gear  3. Gear  6. Gear  10. Gear  3rd speed clutch  12. Gear  13. Gear then the power is finally transmitted to the output shaft.

65ZV-2 US 32-16 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Forward 4th speed power flow path

2 3

12 8

65V2E32012

The power from the torque converter is transmitted to; F-clutch  2. Gear  3. Gear  6. Gear  4. Gear  8. Gear  4th speed clutch  12. Gear  13. Gear then the power is finally transmitted to the output shaft.

65ZV-2 US 32-17 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Reverse 1st speed power flow path

1 F

6 7 1ST

2ND

11 12

13 3RD

4TH

65V2E32013

The power from the torque converter is transmitted to; R-clutch  1. Gear  4. Gear  1st speed clutch  7. Gear  11. Gear  12. Gear  13. Gear then the power is finally transmitted to the output shaft.

Reverse 2nd, 3rd, and 4th speeds power flow path Refer to the transmission routes of the above reverse 1st speed and the forward 2nd, 3rd, and 4th speeds.

WARNING In models 65TMV(-2), 65ZV(-2) and 70ZV equipped with a Kawasaki Transmission, if there is a failure in range selection of gears 1~3, the transmission will automatically default to 4th gear. This could result in the machine moving unexpectedly with a forward or reverse clutch pack accidentally engaged.

65ZV-2 US 32-18 32 Function & Structure Torque Converter and Transmission Group Hydraulic System Diagram

Hydraulic System Diagram

7 9 21

14 8

10 11 F

13 SOL F 12 1st

SOL R

2nd

SOL 1st

3 SOL 2nd

17 3rd

4th

20 19

SOL 3/4

65V2E32014

1. Transmission case 2. Suction strainer 3. Torque converter pump 4. Line filter 5. Clutch pressure regulator valve 6. Torque converter inlet pressure regulator valve 7. Torque converter 8. Torque converter outlet pressure regulator valve 9. Oil cooler 10. Fixed orifice A 11. Main pressure detection valve 12. Forward solenoid valve

13. Reverse solenoid valve 14. Main accumulator 15. 1st speed shift spool 16. 2nd speed shift spool 17. 1st speed solenoid valve 18. 2nd speed solenoid valve 19. 3rd, 4th speed shift spool 20. 3rd, 4th speed solenoid valve 21. 1st speed pressure detection valve 22. 1st speed accumulator 23. 2nd speed pressure detection valve 24. 2nd speed accumulator

65ZV-2 US 32-19 32 Function & Structure Torque Converter and Transmission Group Hydraulic Circuit Diagram

Hydraulic Circuit Diagram

Transmission case

Torque converter case

10 11

SOL F

SOL R

21 17

SOL 1

SOL 2

For 1st speed

16 15

24 23

SOL 3

20 For 2nd speed

T/C inlet press.

4 7 3 T/C outlet press.

8 9

2 1 120

65V2E32016

65ZV-2 US 32-20 32 Function & Structure Torque Converter and Transmission Group Oil Flow

Oil Flow Oil flow in the torque converter line From torque converter gear pump to torque converter Oil from pump (3) flows through line filter (4) and clutch pressure regulator valve (5), moving the regulator piston to the right against the spring force, to torque converter (7). Torque converter inlet pressure regulator valve (6) installed between regulator valve (5) and torque converter (7) maintains the torque converter inlet oil pressure at a specified value set at 0.3~0.7 MPa (3~7 kgf/ cm2) (43~100 psi).

Return oil from torque converter Return oil from the torque converter flows through the torque converter housing into torque converter outlet pressure regulator valve (8), moving the spool to the left side against the spring force, opening the cooler port to adjust torque converter oil pressure to the specified pressure 0.15~0.5 MPa (1.5~5 kgf/cm2) (21~71 psi).

Return oil from cooler Oil cooled by oil cooler (9) flows through the lubrication oil passages in the transmission housing to lubricate all the bearings and to cool the clutch plates. After that, the oil is drained into the oil pan.

Oil flow to the clutches To forward and reverse clutches Oil maintained at a specified pressure 1.8~2.1 MPa (18~21 kgf/cm2) (256~299 psi) by regulator valve (5) flows through fixed orifice A (10) and pressure detection valve (11), into forward/reverse solenoid valve (12)(13). When the clutch is shifted to the forward, forward solenoid valve (12) is "ON", the oil maintained at a specified pressure flows to the forward clutch piston chamber.

To speed clutches The oil fed from the pump is regulated to the specified pressure by clutch pressure regulator valve (5), and then, directed through the fixed orifice A, 1st speed shift spool (15), 2nd speed shift spool (16), then 3rd, 4th speed shift spool (19) to the selected speed clutch piston chambers. The circuit is a series circuit and when all of the solenoid valves for 1st, 2nd, 3rd · 4th speed are in OFF position, the oil flows to the 4th clutch piston chamber. Therefore, no clutches are connected at the same time under the circuit. When the 1st and 2nd speed position, which involves a high reduction ratio are selected, a certain amount of shock would occur. To prevent this, the accumulators for the 1st and 2nd speed clutches are used to raise the clutch pressure slowly when the 1st and 2nd speed clutches are engaged (detailed explanation later).

65ZV-2 US 32-21 32 Function & Structure Torque Converter and Transmission Group T/C and T/M Oil Circulation

T/C and T/M Oil Circulation (S/N 5001~5014)

Rear chassis

Water IN Water OUT

Torque converter oil cooler

Transmission

Transmission oil filter Transmission control valve

K65V2E32001

65ZV-2 US 32-22 32 Function & Structure Torque Converter and Transmission Group T/C and T/M Oil Circulation (S/N 5015~)

Water IN Water OUT

Torque converter oil cooler

Rear chassis

Transmission

Transmission oil filter

Transmission control valve

K65V2E32002

65ZV-2 US 32-23 32 Function & Structure Torque Converter and Transmission Group Control Valve

Control Valve Main control valve

3rd, 4th speed control valve

14 19

15 SOL 3/4

70ZV32038

SOL

17 SOL

SOL

70ZV32037

1. — 2. — 3. — 4. — 5. — 6. — 7. — 8. — 9. — 10. — 11. Main pressure detection valve 12. Forward solenoid valve 13. Reverse solenoid valve 14. Main accumulator 15. 1st speed shift spool 16. 2nd speed shift spool 17. 1st speed solenoid valve 18. 2nd speed solenoid valve 19. 3rd, 4th speed shift spool 20. 3rd, 4th speed solenoid valve

65ZV-2 US 32-24 32 Function & Structure Torque Converter and Transmission Group Control Valve

Oil port layout Layout of ports on mounting surface of control valve (at T/M case side) Main control valve To forward clutch

To reverse clutch

Bolt hole Drain port leading to T/M case. B

To 1st speed clutch B B

To 2nd speed clutch

B B

From regulator valve B

B B

To solenoid pilot oil pressure port of 3rd, 4th speed shift spool

To clutch oil pressure port of 3rd, 4th speed shift spool

B B D B

Drain port (total 3 places)

Bolt hole (total 20 places) 70ZV32039

3rd, 4th speed control valve Bolt hole (total 6 places)

Drain port to T/M case (total 2 places)

To 3rd, 4th clutch oil pressure port from main control valve

From regulator valve D

To 4th speed clutch

To 3rd speed clutch

70ZV32040

65ZV-2 US 32-25 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

Modulation Mechanism When forward/reverse or speed changing, the modulation mechanism works to reduce the time required for clutch engagement (time lag), to prevent the shock at clutch engagement, to improve the work efficiency and durability of the power system, and to ensure operator's comfort. For such effects, the modulation mechanism controls the clutch oil pressure rising time as follows:

Clutch control oil pressure curve Clutch pressure MPa (kgf/cm2)

P2 P1 t2

High pressure holding

Pressure increase Initial oil feeding

Time (sec)

High pressure holding 70ZV32041

P: MPa (kgf/cm2)(psi) t: sec

Std. value Speed range 1,2 speed 3,4 speed (at Engine high idle)

1.4~1.7 1.8~2.1 1.1~1.7 0.1~0.4 (14~17) (18~21) (1~4) (256~ (200~ (14~57) 0.8~1.4 300) 240)

0.2

65ZV-2 US 32-26 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

Modulation mechanism operation Before the shift lever is moved (traveling or stop condition) (high pressure holding)

Accumulator

(2)

From regulator valve

To solenoid valve Fixed orifice A

(1)

Pressure detection valve

(5)

(4)

(3) To forward, reverse and speed clutch 70ZV32021

The pressure detection valve spool is pushed to the left end against the spring force by the high clutch oil pressure and the accumulator is filled with the oil pressing the spring.

65ZV-2 US 32-27 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

When the shift lever is moved (1) (Initial oil feeding to clutch piston chamber)

Accumulator (discharging)

(2)

From regulator valve

To solenoid valve

(1)

Fixed orifice A

(6) Pressure detection valve

(5)

(4)

(3) To forward, reverse and speed clutch 70ZV32022

When the shift lever is moved, the circuit pressure between the fixed orifice A and the clutch drops until oil fills the piston chamber of the clutch that is engaged and force the piston against the clutch plates. This drop in circuit pressure causes a drop in the pressure forcing the accumulator piston to the right, so the spring moves the piston to the left, and the oil in the accumulator is directed to the piston chamber of the clutch that is engaged. At this time, oil discharged from the accumulator flows through passages (2), (4) and (5) into the clutch piston chamber. At the same time, the pressure forcing the pressure detection valve spool to the left drops and the return spring moves the spool to the right. Under this condition, oil from the regulator valve flows through the fixed orifice A, passage (1) and orifice (6) in the spool, and into the clutch piston chamber, and this keeps the low oil pressure in the piston chamber.

65ZV-2 US 32-28 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

When the shift lever is moved (2) (clutch oil pressure increase)

Accumulator (being filled)

(2)

From regulator valve

To solenoid valve Fixed orifice A

(1)

(6)

Pressure detection valve (4) (5)

(3)

To forward, reverse and speed clutch 70ZV32023

After oil from the accumulator initially fills the clutch piston chamber, the oil from the regulator valve flows through passages (1), (6) and (3), through passages (5) and (2), and into the accumulator, filling it. Consequently, clutch oil pressure rises gradually to transmit torque smoothly. As clutch oil pressure rises, the force on the pressure detection valve spool also increases gradually and moves the spool to the left. When the clutch oil pressure reaches about 1.4 MPa (14 kgf/cm2) (199 psi), passages (1) and (4) are connected, maintaining the specified clutch oil pressure. The oil in the accumulator which is filled is now ready to be supplied to the clutch piston chamber the next time the clutch is shifted.

65ZV-2 US 32-29 32 Function & Structure Torque Converter and Transmission Group Accumulator

Accumulator Accumulator for 1st and 2nd speed clutch

When the 1st (2nd) speed position, which involves a high reduction ratio, is selected, a certain amount of shock would occur. To prevent this, an accumulator just for the 1st (2nd) speed clutch is used to raise the clutch pressure slowly when 1st (2nd) speed clutch is engaged.

[1]

[2] 3

From speed shift spool 1st (2nd) accumulator

Pressure detection valve

From speed shift spool

To 1st clutch

70ZV32024

1. Before shifting to 1st (2nd) speed Because there is no clutch oil pressure acting on the 1st (2nd) speed clutch piston, the piston of 1st (2nd) speed accumulator (1) and the spool of pressure detection valve (4) are forced to the right by springs (2) and (5) respectively. 3

70ZV32026

3. During shifting to 1st (2nd) speed (B) When the piston of 1st speed accumulator (1) has been stopped by stopper (3), oil from passage [2] starts to move the spool of pressure detection valve (4) to the left. Consequently, the oil filling the accumulator flows through passage [1] and pressure detection valve (4) and drains into the drain port. (Discharging of the accumulator.)

From speed shift spool

To 1st clutch

70ZV32027

[1]

From speed shift spool

To 1st clutch

70ZV32025

2. During shifting to 1st (2nd) speed (A) Oil from the speed range shift spool flows through pressure detection valve (4) and passage [1] into the 1st (2nd) speed accumulator, pushing piston (1) to the left against stopper (3). (Charging of the accumulator.)

4. When shifting to 1st (2nd) speed is completed After the oil in the accumulator has been discharged into the drain port, there is still oil pressure in the clutch port. Therefore, the spool of pressure detection valve (4) remains at the left with the oil pressure and the force of spring (5) balanced.

65ZV-2 US 32-30 32 Function & Structure Torque Converter and Transmission Group Clutch Solenoid Valve

Clutch Solenoid Valve For forward/reverse and speed clutches After power-off (clutch disengaged status) 5

P 7

T To T/M oil pan

A From clutch piston chamber

1. Coil 2. Plunger 3. Rod 4. Spring 5. Spool 6. Stopper 7. Manual control push button When the power of the coil is turned off, spool (5), push rod (3), and plunger (2) are returned fully to the right, and port P is closed. The line between port A and T is opened, and the clutch is disengaged. Under such a condition, pressing manual control push button (7) (for emergency) opens the line between port P and A, and engages the clutch. Releasing the manual control push button returns the spool fully to the right, and disengages the clutch.

70ZV32028

65ZV-2 US 32-31 32 Function & Structure Torque Converter and Transmission Group Clutch Solenoid Valve

After power-on (clutch engaged status) From clutch pressure regulator

A To clutch piston chamber 70ZV32029

When the power is supplied to the coil, the magnetic power attracts the plunger to the left, and the line between port P and A is opened. Pressure oil flows into the clutch piston chamber. The clutch is engaged.

65ZV-2 US 32-32 32 Function & Structure Torque Converter and Transmission Group

MEMO

65ZV-2 US 33-1 33 Check & Adjustment Torque Converter and Transmission Group

33 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure ................................................. 33-2

65ZV-2 US 33-2 33 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure

Clutch Oil Pressure Measuring clutch oil pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men. - Prohibit any person from walking into dangerous areas. - Near articulation area of the machine - Under the machine - Around the engine. - In front of or behind the machine

65ZV-2 US 33-3 33 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure

9 1 8 6 View from A

7 A

5 3

View from B

65V2E33001

Oil pressure MPa (kgf/cm2) (psi) No.

Measuring port location

Measuring port size

Engine revolution (min-1) (rpm) 800

2,400

0.1 (1.3) (18) or more

0.3~0.7 (3~7) (43~100)

0.1 (1.0) (14) or more

0.15~0.5 (1.5~5) (21~71)

1.5 (15) (213) or more

1.8~2.1 (18~21) (256~299)

Shift lever position

Torque converter inlet pressure

Torque converter outlet pressure

Main oil pressure

Clutch oil pressure

1ST

PF1/4

1.5(15)(213) or more

1.8~2.1 (18~21) (256~299)

All speed range All speed range

2ND

3RD

4TH

Lubrication oil pressure

PF3/8

0.002~0.07 (0.02~0.7) (0.3~10)

0.08~0.2 (0.8~2.4) (11~34)

All speed range

65ZV-2 US 33-4 33 Check & Adjustment Torque Converter and Transmission Group

MEMO

65ZV-2 US 42-1 42 Function & Structure Hydraulic Group

42 Function & Structure Hydraulic Group Flushing Hydraulic Circuit........................................ 42-2 Cautions on Hydraulic Parts Replacement.............. 42-3 Hydraulic Circuit Symbols ....................................... 42-4 Hydraulic System Operation.................................... 42-8 Layout of Hydraulic Units ........................................ 42-10 Hydraulic Tank......................................................... 42-11 Hydraulic Pump ....................................................... 42-17 Hydraulic Cylinder ................................................... 42-20 Loading System ...................................................... 42-23 Reducing Valve (for Pilot Pressure) ........................ 42-24 Pilot Valve (TH40MS) .............................................. 42-25 Multiple Control Valve (KML22/2T).......................... 42-30 Adapter (Orifice) ...................................................... 42-42 Ride Control (OPT).................................................. 42-43 Steering System ...................................................... 42-53 Priority Valve ........................................................... 42-55 Orbitrol® ................................................................... 42-59 Accumulator ............................................................ 42-70 Efficient Loading System (OPT) .............................. 42-72 Fan Motor System ................................................... 42-78 Fan Motor Line ........................................................ 42-79 Reversing Fan Motor Line ....................................... 42-90 Secondary Steering (OPT) ...................................... 42-93

65ZV-2 US 42-2 42 Function & Structure Hydraulic Group Flushing Hydraulic Circuit

Flushing Hydraulic Circuit Purpose of flushing

Debris To tank

95ZV42001

If the inside of a cylinder, pump, or a valve of the hydraulic system is broken, the debris will be sent into the hydraulic line together with the oil. Most of the debris will flow into the return filter or hydraulic tank. However, there are some debris that will remain in the valves, cylinders, or pipes. Therefore, even if the damaged cylinder or valve is replaced, the debris sticking in other valves, cylinders, or pipes will break loose and then is fed into the cylinders, where the debris may damage the inside of the cylinders, or stick into the valve spools or relief valves, and cause another malfunction. To prevent such problems, be sure to remove all the debris from the system.

65ZV-2 US 42-3 42 Function & Structure Hydraulic Group Cautions on Hydraulic Parts Replacement

Cautions on Hydraulic Parts Replacement After oil or a part is replaced, malfunction or seizure may occur during running-in. Such trouble is often caused by faulty air bleeding or lubrication after replacement. After replacing oil or a part, be sure to observe the following work procedure to prevent occurrence of trouble. Work procedure 1. In the case of new oil pump, lubricate its inside with new oil prior to installation, and confirm that it can be turned smoothly by hand. 2. After the oil pump or cylinder was made empty for oil replacement, repair, etc., restart the operation as follows. (a) Before installing pipes, pour new oil into the pump or the cylinder. (b) Operate the engine at low-idling speed for 5 minutes or more. Do not operate any hydraulic functions during this period. (c) While keeping the engine at low-idling speed, move each cylinder 5 times or more respectively. At this time, - Move each cylinder to a place near the stroke end so that hydraulic pressure does not go over relief. - Lower the boom slowly. Dump the bucket slowly. Do not activate the make up valves from rapid activation of circuits. (d) Perform general operations, and confirm that abnormal sound, heat generation and any other abnormality is not detected. (e) Observe the hydraulic oil level sight gauge and confirm that there are no bubbles in the hydraulic oil.

65ZV-2 US 42-4 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Hydraulic Circuit Symbols Hydraulic lines

Pumps & motors (1)

Working hydraulic line

Fixed displacement, Hydraulic pump (1) Unidirectional (2) Bidirectional

Pilot line Drain line

(2)

(1) Variable displacement, Non-compensating hydraulic pump (1) Unidirectional (2) Bidirectional

Lines joining

Flexible line

(2)

(1) Fixed displacement, Rotary hydraulic motor (1) Unidirectional (2) Bidirectional

Lines passing

Line to tank (Above fluid level)

(2)

(1)

Line to tank (Below fluid level)

Variable displacement, Rotary hydraulic motor (1) Unidirectional (2) Bidirectional

Hydraulic tank (Pressurized type)

Fixed restriction

(2)

Cylinders (1)

Rotary joint (1) one line (Unidirectional) (2) three line (Bidirectional)

(2)

(1)

(2)

(1)

(2)

(1)

(2)

(1)

(2)

Single acting cylinder (without spring)

Single acting cylinder (with spring)

Double acting cylinder (single rod)

Double acting cylinder (double rod) (1) detail symbol (2) mnemonic symbol

65ZV-2 US 42-5 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Operation methods

Pressure control valve

Spring

Single flow path valve, Normally closed

Adjustable spring

Single flow path valve, Normally open

Control methods Pressure relief valve

Lever

Push button Unloading valve Pedal or treadle

Mechanical control Sequence valve Plunger

Pressure reducing valve

Spring

Solenoid control Single acting solenoid

Flow control valve

Double acting solenoid

Flow control valve, Adjustable non-compensated

Electric motor control Unidirectional

Pressure compensated flow control valve

M fixed

Bidirectional

M variable

Detent

Flow dividing valve

65ZV-2 US 42-6 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Directional control valve

Check valve

Two position Two ports

Check valve

Three position Four ports

Check valve Pilot operated

Four ports with restrictor

Shuttle valve

Two position Two ports Mechanical control Spring offset Pressure control Two position Three ports Pressure control

Spring offset Solenoid control Restrictor Two ports

Three ports

Four ports

Servo valve

65ZV-2 US 42-7 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Miscellaneous hydraulic symbols (1) Hydraulic tank (1) Vented (2) Pressurized

(2)

Manual shut off valve

Pressure switch

Accumulator

Electric motor

Internal combustion

Power source

Filter or strainer

Heater

Cooler

Pressure gauge

Temperature gauge

Flow meter

65ZV-2 US 42-8 42 Function & Structure Hydraulic Group Hydraulic System Operation

Hydraulic System Operation Hydraulic system operation outline

Return oil from the cylinders flows through the valve to the oil cooler, return filter (12) and into the hydraulic tank.

The hydraulic system consists of the following systems: - Loading system - Steering system

Even if no hydraulic pump supplies oil to the loading and pilot control circuits due to trouble, or if the engine is shut off, the boom can be lowered to the ground by the pressure in accumulator (33) in the brake circuit in case of an emergency.

- Fan motor system - Ride control system (OPT)

Steering system - Secondary steering (OPT) The steering system consists of the following components.

Loading system The loading system consists of the following components. All numbers base on page 92-5. - Hydraulic pump (1) - Unloader valve (22) - Line filter (39) - Check valve (32) - Reducing valve (38) - Pilot valve (16) - Multiple control valve (3) - Boom cylinders (5) - Bucket cylinder (6) Oil from pump (1) flows to pilot valve (16) through unloader valve (22), line filter (39), check valve (32) and reducing valve (38). Oil to pilot valve (16) is reduced to 3.5 MPa (36 kgf/cm2) (512 psi) by reducing valve (38). When the pilot control lever is operated, the pilot valve line is opened, and the oil pressure is generated depending on the position of the pilot control lever. The pilot pressure entering the oil pack to multiple control valve (3) moves the spool against its return spring. The spool press-in distance (displacement) depends on the pilot valve pressure. Oil from the loader pump is then directed through multiple control valve (3) to boom cylinders (5) and bucket cylinder (6).

- Hydraulic pump (1) - Priority valve (15) - Orbitrol® (14) - Accumulator (34) - Steering cylinder (8) Oil from pump (1) flows to Orbitrol® (14) through the priority valve (15). When the steering wheel is turned, an amount of oil proportional to the turning speed is sent from pump (1) to steering cylinder (8) through priority valve (15) and Orbitrol® (14). When the steering wheel is not operated, almost all of the hydraulic oil discharged from pump (1) is supplied to the loading circuit. Priority valve (15) detects the resistance of the hydraulic oil passing through Orbitrol® (14), namely the speed of the steering wheel’s rotation and the amount of oil, and then distributes oil to the loading and steering circuits. Accumulator (34) is provided to prevent shock at the time of starting and stopping the steering wheel. While the steering wheel is not turned, almost all hydraulic oil from steering pump (1) is sent to the loading line by the action of the flow control spool in priority valve (15). Oil returns from steering cylinders (8) flows through orbitrol® (14) and returns to the hydraulic tank. Finally it returns to the tank through return filter (12).

65ZV-2 US 42-9 42 Function & Structure Hydraulic Group Hydraulic System Operation

Fan motor system The fan motor system consists of the following components. - Hydraulic pump (1) - Unloader valve (22) - Fan motor (71) The cooling fan is driven by hydraulic motor (71). The pressure oil from unloader valve (22) flows into the port P of fan motor assy, enters fan motor (71) and flow control valve, and then, turns fan motor (71). Three kinds of signals sent from the ECM, torque converter oil temperature sensor, and hydraulic oil temperature sensor, are input into the MCU as information to regulate the maximum fan revolution. The fan revolution is regulated by the oil amount supplied to fan motor (71). Oil amount supplied to fan motor (71) is changed in proportion as the engine revolution and the opening area of the flow control valve of fan motor (71).

Ride control system (OPT) Refer to "Ride Control (OPT)" page 42-43 for the information.

Secondary steering (OPT) Refer to "Secondary Steering (OPT)" page 42-93 for the information.

65ZV-2 US 42-10 42 Function & Structure Hydraulic Group Layout of Hydraulic Units

Layout of Hydraulic Units 1

10 (S/N ~5136) 7

(S/N 5137~) 10

10 (S/N ~5136) K65V2U42002

1. Multiple control valve 2. Pilot valve 3. Orbitrol® 4. Priority valve 5. Hydraulic pump (3 section) 6. Fan motor

7. Bucket cylinder 8. Boom cylinder 9. Steering cylinder 10. Accumulator (for steering) 11. ELS valve (OPT) 12. Secondary steering pump (OPT)

65ZV-2 US 42-11 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic Tank Hydraulic Tank (S/N 5001~5200)

8 7 14

A 6

A-A 12 13

3 1 4 2 15

16 (S/N 5001~5050)

10 K65V2U42003

1. Hydraulic tank 2. Oil level sight gauge 3. Breather valve (tank cap) 4. Filter 5. Suction strainer 6. Return filter element 7. Relief valve 8. Spring

9. Cover 10. Drain plug 11. Inspection hole cover 12. Return pipe (for brake) 13. Return pipe (for pilot) 14. Vent pipe (to axle housing) 15. Oil level sensor 16. Oil temperature sensor 17. Lock bolt

65ZV-2 US 42-12 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank breather valve (tank cap)(S/N 5001~5200) 1

4 5

a b c

1. Cover 2. Filter element 3. Spring (for exhaust valve) 4. Valve assembly (a) Exhaust valve (b) Suction valve (c) Air bleeder valve 5. Spring (for suction valve) 6. Key (same as starter key) 7. Attaching bolts (3 pcs) socket head

Viewed from section A

70ZV42005

When the pressure inside the hydraulic tank drops below the outside air pressure, the outside air flows through filter element (2) and to valve assembly (4). Suction valve (b) is then opened to let the air flow into the tank. When the air pressure inside the hydraulic tank rises to a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), Exhaust valve (a) is lifted (opened) so that the air can flow out of the tank through filter element (2). One cycle (down and up) of the boom applies pressure to the inside of the tank. Therefore 29 kPa (0.3 kgf/cm2) (4.3 psi) pressure is always applied to the inside of the hydraulic tank. The pressure applied to the inside of the hydraulic tank prevents the dust and dirt from being drawn into the tank and improves performance of the pump. The positive pressure pushes the oil to the pump reducing the possibility of pump cavitation. To release the internal pressure from the hydraulic tank, press downward on cover (1). Air bleeder valve (c) will be lowered to release the internal pressure. The pressure is also applied to the axles.

Installing cap The cap can be installed in any boom or bucket position.

65ZV-2 US 42-13 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic Tank (S/N 5201~)

(S/N 5401~)

1. Hydraulic tank 2. Oil level sight gauge 3. Breather valve (tank cap) 4. — 5. Suction strainer 6. Return filter element 7. Relief valve 8. Spring

9. Cover 10. Drain plug (S/N 5401~ square socket head) 11. Inspection hole cover 12. Return pipe (for brake) 13. Return pipe (for pilot) 14. Vent pipe (to axle housing) 15. Oil level sensor 16. Oil temperature sensor 17. Lock bolt

65ZV-2 US 42-14 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank breather valve (tank cap)(S/N 5201~) When the pressure inside the hydraulic tank drops below the outside air pressure, the outside air flows through filter element (2) and to valve assembly (4). Suction valve (b) is then opened to let the air flow into the tank.

PUSH

When the air pressure inside the hydraulic tank rises to a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), Exhaust valve (a) is lifted (opened) so that the air can flow out of the tank through filter element (2).

1 6

One cycle (down and up) of the boom applies pressure to the inside of the tank.

Therefore 29 kPa (0.3 kgf/cm2) (4.3 psi) pressure is always applied to the inside of the hydraulic tank. The pressure applied to the inside of the hydraulic tank prevents the dust and dirt from being drawn into the tank and improves performance of the pump.

The positive pressure pushes the oil to the pump reducing the possibility of pump cavitation.

a b 5 K65D2J42001

1. Cap 2. Filter element 3. Spring (for exhaust valve) 4. Valve assembly (a) Exhaust valve (b) Suction valve (Air bleeder valve) 5. Spring (for suction valve) 6. Hex nut

To release the internal pressure from the hydraulic tank, press down cap (1). Air bleeder valve (b) will be lowered to release the internal pressure. The pressure is also applied to the axles.

Installing cap The cap can be installed in any boom or bucket position.

65ZV-2 US 42-15 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank specifications Type

Semi-closed type

Capacity (at center of oil level sight gauge) L (gal)

70 (18.5 US gal)

Filtration area (cm ) Return filter

10,400

Filtration particle size (µm)

Relief valve opening pressure (filter bypass) (MPa) (kgf/cm2) (psi) Suction strainer

Loading Pilot & brake Steering

0.1±0.02 (1.0±0.2) (14±2.8)

Filtration area (cm2)

1,640

Filtration particle size (µm)

105 2

Suction valve setting pressure (kPa) (kgf/cm ) (psi) 2

Discharge valve setting pressure (kPa) (kgf/cm ) (psi) Breather valve (oil filling port) (S/N 5001~5200)

29 (0.3) (4.3)

Filtration area (cm )

235

Filtration particle size (µm)

Pushing load before turning cap required for venting pressure, removing or installing cap N (kgf) (lb) Suction valve setting pressure (kPa) (kgf/cm2) (psi) Breather valve (oil filling port) (S/N 5201~)

1 (0.01) (0.14)

Discharge valve setting pressure (kPa) (kgf/cm ) (psi) 2

186~216 (19~22) (42~48) 3.9 (0.04) (0.57) 29 (0.3) (4.3)

Filtration area (cm )

160

Filtration particle size (µm)

65ZV-2 US 42-16 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic oil level check

Bucket on ground

Hydraulic tank

Oil level sight gauge

(18.5 US gal)

70 L

Cold level

70ZV42006

Before checking the hydraulic oil level, observe the following items: - Check that the machine is on level ground. - Check the hydraulic oil level before operation (when oil is not warm). - Lower the boom to the lowest limit, and set the bucket level on the ground. Check that the oil level is at the center of the oil level sight gauge. Oil amount 70 L (18.5 US gal) Note If the oil is at operating temperature 60°C ~ 90°C (140°F ~ 200°F) the oil level may be at or near the top of the oil level sight gauge.

65ZV-2 US 42-17 42 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic Pump

9 12

10 13 1

11 5

65T2U42013

8. Oil seal 9. Snap ring 10. Pin 11. O-ring 12. Stud bolt / nut 13. Bolt 14. Bushing

1. Drive gear 2. Driven gear 3. Bracket 4. Gear case 5. Carrier 6. Cover 7. Wear plate

Hydraulic pump specifications Applicable circuit Theoretical discharge Maximum operation pressure Maximum speed

cm3/rev MPa (kgf/cm2) (psi)

Front

Center

Rear

For steering

For loading

For brake and pilot

45.6

26.7

14.5

20.6±0.5 (210±5) (2,986±71)

min-1 (rpm)

The triple gear pump is used for the steering, loading, brake and pilot.

3,000

65ZV-2 US 42-18 42 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic pump principle

Inlet

Outlet

Inlet

Outlet

Inlet

Outlet

95ZV42040

The oil at the inlet area is taken in the cavities between the gear teeth right after disengagement and transferred towards the outlet area enclosed in between the teeth and the gear casing. When the gear teeth mesh again, the oil is extruded out of the tooth cavities and forwarded to the outlet.

65ZV-2 US 42-19 42 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic pump wear plate

Both sides of the gear consists of floating type pressure plates having balancing functions. The pressure plates maintain optimum clearance on both sides of the gear (pressure balance mechanism) so that the high volumetric efficiency is ensured.

General structure of pressure plate Suction

Discharge

Rotating gears feed the pressurized oil along the circumference of the case to the outlet port. The pressurized oil is also sent to the high-pressure area in the rear of the pressure plate. The pressure plate is pressed to the gear side so that the clearance between the pressure plate and the side surface of the gear is kept very small. The pressing force to the plate is adjusted to an appropriate value by setting the optimum high-pressure area of the plate. The high-pressure area in the rear of the pressure plate is enclosed by the plate seal, back-up seal, and isolation plate.

Discharge High pressure area Back-up ring

To prevent the gear-sealing area from extremely high pressure due to confined oil, there is a confined oil bypass groove at the gear-sealing area of the pressure plate.

Hydraulic pump bushing lubrication

O-ring

The lubrication system uses the oil fed from the pressurized tank.

Suction

Oil groove for lubricating bearing

Part of the oil fed from the inlet port is sent to the bushings to lubricate them. After that, the oil is returned to the inlet side and then sent to the discharge side. Bushings require lubrication to maintain a long service life. Avoid bushing damage due to a lack of lubrication oil by:

Suction

Starting up a new pump with oil supplied to it. - Allow new pump to idle (low rpm/no load) for 5 minutes. Confinement prevention groove

Discharge

115ZV42006

- Use the proper viscosity for the coldest possible start up temperature. Change viscosity if seasonal temperature changes are great (more than 20°C (68°F)).

65ZV-2 US 42-20 42 Function & Structure Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder 19. Buffer ring 20. O-ring 21. Wear ring 22. Plug 23. O-ring 24. Bushing 25. Dust seal 26. Piston packing

10. Square ring 11. Slipper ring 12. O-ring 13. O-ring 14. Back-up ring 15. U-packing 16. Back-up ring 17. Dust seal 18. Stop ring

1. Cylinder tube 2. Piston rod 3. Piston 4. Piston nut 5. Rod cover 6. Bushing 7. Bolt 8. Stop ring 9. Wear ring

Boom cylinder

24, 25

21 10, 11 9 3

15 13 14 6 5

17 18

7 12

: Piston nut (4): 2,501 N-m (255 kgf-m) (1,845 lb-ft) : Bolt (7): 481 N-m (49 kgf-m) (355 lb-ft)

65ZV42005

65ZV-2 US 42-21 42 Function & Structure Hydraulic Group Hydraulic Cylinder

Bucket cylinder (S/N 5001~5050)

24,25

4 21 26 21

2 1

18 6 13, 14 19 15 17

22, 23 (Gauge port PF1/4)

24, 25

7 K65V2E42003

(S/N 5051~)

24, 25

4 21 26 21

2 1

22, 23 (Gauge port PF1/4)

18 6 13,14 19 15 17

24, 25

7 K65V2U42004

: Piston nut (4): 4,600±230 N-m (469 kgf-m) (3,393±170 lb-ft) : Bolt (7): 880±90 N-m (89.7 kgf-m) (649±67 lb-ft)

Steering cylinder

24, 25

4 21

26 21

14 19 15 20 5 17

24, 25

K65V2J42001

: Piston nut (4): 600±30 N-m (61±3 kgf-m) (441±22 lb-ft) : Rod cover (5): 300±30 N-m (31±3 kgf-m) (224±22 lb-ft)

65ZV-2 US 42-22 42 Function & Structure Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder specifications mm (in) Inner diameter x rod diameter x stroke Boom cylinder

Pin hole (inner diameter x width)

Piston rod

ø70 x 151 (2.75 x 5.94)

Cylinder

ø70 x 88.5 (2.75 x 3.48)

Inner diameter x rod diameter x stroke Bucket cylinder

Pin hole (inner diameter x width)

ø140 x ø80 x 491 (5.51 x 3.15 x 19.33)

Piston rod

ø70 x 90 (2.75 x 3.54)

Cylinder

ø70 x 90 (2.75 x 3.54)

Inner diameter x rod diameter x stroke Steering cylinder

ø120 x ø65 x 730 (4.72 x 2.56 x 28.74)

ø65 x ø40 x 374 (2.56 x 1.57 x 14.72)

Piston rod

ø40 x 50 (1.57 x 1.97)

Cylinder

ø40 x 50 (1.57 x 1.97)

65ZV-2 US 42-23 42 Function & Structure Hydraulic Group Loading System

Loading System The pilot operation system uses the pilot valve pressure to control the spool of the multiple control valve and move the boom cylinder(s) and bucket cylinder(s). When the control lever is operated, the pilot valve line is opened, and the oil pressure is generated depending on the position of the control lever. The pilot pressure entering the oil pack to the multiple control valve moves the spool against its return spring. The spool press-in distance (displacement) depends on the pilot valve pressure. Control lever

Oil from the loader pump is then directed through the valve to the cylinder.

Pilot valve

Return oil from the cylinders flows through the valve to the oil cooler, return filter and into the tank. Oil to the pilot valve is supplied from the brake line while being reduced to 3.5 MPa (36 kgf/cm2) (512 psi) by the reducing valve.

Valve (for safety lock) Reducing valve

From brake line

Oil packs

Multiple Oil packs control valve

From steering valve Cooler

P Return filter

85V2E42004

Even if no hydraulic pump supplies oil to the loading and pilot control circuits due to trouble, or if the engine is shut off, the boom can be lowered to the ground by the pressure in the accumulator in the brake circuit in case of an emergency.

65ZV-2 US 42-24 42 Function & Structure Hydraulic Group Reducing Valve (for Pilot Pressure)

Reducing Valve (for Pilot Pressure) Pressure adjustment stud Locknut PPDB-LAN CXCD-XAN

Ball

CXCD-XAN

Passage Y (T)

(P) (TA) (ACCR)

(PARKING)

(ACCF)

(PA) (Z1)

(Z)

Orifice 2

From front brake accumulator circuit

(Z2)

(PPI)

Tank Valve assembly

Note: Valve is shown rotated 180º from normal.

A Orifice 1

Passage Z

Plunger

Pilot oil circuit

This valve provides pilot oil pressure to operate the park brake and loader pilot valve functions. The oil fed from the brake accumulator circuit flows into the pilot oil circuit by way of passage Z. The oil pressure in the pilot oil circuit is applied also on chamber C by way of orifice 1. When the oil pressure in the pilot oil circuit is at or above the set pressure, the oil in chamber C unseats the ball by way of orifice 2, and escapes to the tank by way of passage Y. As a result, the pressure in chamber C decreases, then the plunger moves up and closes passage Z so that the pressure on the pilot oil circuit side does not exceed the set pressure.

T Hydraulic circuit diagram

85V2E42005

When the oil pressure on the pilot oil circuit side becomes less than the set pressure, the ball moves down and the pressure at chamber C becomes equivalent to the pressure on the pilot oil circuit side (B). As a result, the plunger moves down by a spring, opens the passage Z, then introduces the accumulator pressure to the pilot oil circuit side so that the pressure is maintained at the specified value. This pressurized oil is supplied to the multiple control valve oil pack through the pilot valve and moves the multiple control valve spool. Set pressure 3.5 MPa (36 kgf/cm2) (512 psi)

65ZV-2 US 42-25 42 Function & Structure Hydraulic Group Pilot Valve (TH40MS)

Pilot Valve (TH40MS) The pilot valve is remote control type with one lever. It controls four directions and contains four pressure reducing valves in the valve case that control the secondary pressure.

The pilot valve applies the oil pressure to the multiple control valve in proportion to the operating angle of the lever. It controls the spool of the multiple control valve and moves the boom cylinder(s) and bucket cylinder.

The detent solenoid valve is installed at the boom raise, boom float and bucket roll back position. Installation position detail

16.4º

Bucket roll back

Boom raise Boom down

16.4º

16. 4º

Bucket dump

A Outside

Bucket dump

(T)

Boom down 1 4 T P 32

Front

Rear

Pilot valve

Boom raise

(P)

Bucket roll back

Pilot valve filter

Inside

A - A Oil port (Viewed from top) 50ZV42014

Note The pilot valve filter is installed on P port.

65ZV-2 US 42-26 42 Function & Structure Hydraulic Group Pilot Valve (TH40MS)

Pilot valve specifications Maximum control pressure MPa (kgf/cm2) (psi) 0~4.4 (0~45) (0~640) Operating angle

Boom or bucket

±16.4º

Both boom and bucket

±21.5º

Solenoid

Voltage

DC 24 V

Resistance

About 63 

Pilot valve performance chart MPa (kgf/cm2) (psi) 4.0 (40) (580)

Bucket roll back

3.0

Secondary pressure

MPa (kgf/cm2) (psi) 4.0 (40) (580)

2.2 2.0

1.0

Bucket dump

3.0 2.4 2.0

1.0

0.59 0.39 0

0.8

6.5

0.8

Push rod stroke (mm)

MPa (kgf/cm2) (psi) 4.0 (40) (580)

Boom down

3.0 2.98

Secondary pressure

MPa (kgf/cm2) (psi) 4.0 (40) (580)

2.0

1.32 1.0

Boom rise

3.0

2.0 1.95

1.0 0.59

0.47

0.8

4 4.3

Push rod stroke (mm)

0.8

6.5

Push rod stroke (mm) 60V2U42006

65ZV-2 US 42-27 42 Function & Structure Hydraulic Group Pilot Valve (TH40MS)

Detent magnet section

7 5 12 11 4

3 2

2 T

Reducing valve section T

T Port

Secondary pressure (multiple control valve oil pack) port

P Port 1

Port 4 (a2) Boom down

Port 3 (a1) Bucket roll back

Port 2 (b2) Boom up

Port 1 (b1) Bucket dump

60ZV42049

1. Spool 2. Return spring 3. Spring for secondary pressure 4. Spring seat 5. Push rod 6. Plate 7. Spring 8. Push rod 9. Solenoid 10. Disc 11. Spring seat 12. Spring

Hydraulic Circuit diagram 60ZV42016

65ZV-2 US 42-28 42 Function & Structure Hydraulic Group Pilot Valve (TH40MS)

Pilot valve operation

10 5 8 4

T Port Secondary pressure (multiple control valve oil pack) port P Port

Secondary pressure (multiple control valve oil pack)

3 2 T

50ZV42016

T Port Secondary pressure (multiple control valve oil pack) port P Port

- When the lever is in the neutral position When the lever [disk (10)] is in the neutral position, spool (1) closes the pump port, and the secondary pressure (multiple control valve oil pack) port is opened to the tank port. Therefore the multiple control valve is held in neutral. At this time, inner pressure 78.5 kPa (0.8 kgf/cm2) (11.4 psi) in the hydraulic tank is applied to the multiple control valve oil pack, but the spool does not move because the operating starting pressure for the multiple spool is 0.32 MPa (3.26 kgf/cm2) (47 psi).

Secondary pressure (multiple control valve oil pack)

50ZV42017

- When the lever is operated When the lever is moved from the neutral, push rod (8) in the detent magnet unit, push rod (5) in the reducing valve unit and spring seat (4) are forced down by disc (10). Spool (1) is forced down by spring (3). Then, the tank port is closed and the pump port is opened. As a result, the pressurized oil from the pump flows into the secondary pressure (multiple control valve oil pressure) port. Then, the spool of the multiple control valve is moved.

65ZV-2 US 42-29 42 Function & Structure Hydraulic Group Pilot Valve (TH40MS) - When the lever is held at certain operating angle When the lever is held at certain operating angle, if the pressure at the secondary pressure (multiple control valve oil pack) side reaches to the point corresponding to spring (3) force for secondary pressure, it is kept a balance between the oil pressure and spring (3) force. When the pressure at the secondary pressure (multiple control valve oil pack) side exceeds the set point, spool (1) closes the pump port to the secondary pressure port, and opens the secondary pressure port to the tank port. (Since the diameter of land of the spool at the tank side is larger than the one at the pump side, the spool is moved up by the pressure area difference of spool.) When the pressure at the secondary pressure (multiple control valve oil pack) side is at the set point or below, the pump port to the secondary pressure port is opened, and the secondary pressure port to the tank port is closed. Thus the pressure at the secondary pressure side is kept constantly.

10 8

6 7

3 2 T

- Detent function works

T Port Secondary pressure (multiple control valve oil pack) port P Port

Secondary pressure (multiple control valve oil pack)

60ZV42018

When the lever is fully shifted to one side, push rod (8) in the detent magnet at the other side is slightly pressed against disc (10). At this time, plate (6) is closely connected to solenoid (9). When the solenoid is energized, plate (6) is kept on the same position.

65ZV-2 US 42-30 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T)

Multiple Control Valve (KML22/2T)

7 3

Pa2

Pb2 C

Pa1

Pb1 B

B 2 P A

(T2)

1 9

(TS) T A-A Boom Spool

Bucket Spool

Bch 4

Hch B1

5 B1R

A1R

6 B-B

A2R Pb1

Pa1

Pb2

Pa2

C-C 65ZV42013

1. Main relief valve 2. Spool (Bucket) 3. Spool (Boom) 4. Overload relief valve (Bucket circuit) (with make-up valve) 5. Make-up valve (Boom circuit) 6. Load check valve 7. Casing 8. Spring cover 9. Cover 10. Gauge port (G 1/4)

65ZV-2 US 42-31 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T)

Boom

Multiple control valve specifications

(Pi) (ROD) A2 B2 (HEAD) Pa2

A2R Pb2

(ROD) A1 B1 (HEAD)

Bucket

Model

KML22/2T

Main relief valve setting pressure

20.6 MPa (210 kgf/cm2) (2,986 psi)

Overload relief valve setting pressure

23.5 MPa (240 kgf/cm2) (3,413 psi)

Hch A1R B1R

Pa1

Pb1 Bch

MR (TS)

Hydraulic circuit

(T2) T

65ZV42066

The bucket priority line is used for the multiple control valve, and consists of the following units: 1. Main relief valve Relieves the pressure when the working pressure exceeds the relief setting pressure. 2. Bucket spool Used for bucket operation, such as roll back, holding a tilt angle, and dumping. 3. Boom spool Used for the boom operation, such as raising, holding height, lowering, and floating. 4. Overload relief valve (With make-up function, on the bucket side) Relieves the high pressure from the cylinder if the pressure is extremely high. Protects the cylinders from a vacuum (negative pressure.) 5. Make-up valve (On the boom side) Protects the cylinders from a vacuum (negative pressure). 6. Load check valve Prevents the reversed oil flow or momentary "load drop".

Over load relief valve installation point Make-up valve installation point

Bucket Boom Bucket Boom

Rod side

Installed

Bottom side

Installed

Rod side

Non-installed

Bottom side

Non-installed

Rod side

Installed

Bottom side

Installed

Rod side

Installed

Bottom side

Non-installed

65ZV-2 US 42-32 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T)

Multiple control valve main relief valve The main relief valve is installed between the pump and the control spool. When the cylinder comes to the stroke end, or if the pressure is above the set pressure, the oil fed from the pump will be discharged into the tank through this valve (main relief valve) to prevent pump and pipe damage.

Main relief valve operation

Adjusting screw

Poppet

Filter

Chamber A Tank port Pump port

Sleeve Adjusting screw

Poppet

Filter

Plunger

Orifice 1

Chamber A Tank port Pump port

Lock nut

Sleeve

Orifice 2

Plunger 70ZV42013

1. When the oil pressure is at the set point or below - The pressurized oil from the pump flows in to the chamber A through the orifice 1, and the plunger is pressed against the sleeve by the pressure area difference of the plunger and the spring force. Also the sleeve completely closes the pump port by the pressure area difference of the sleeve between the pump port side and chamber A side. 2. When the oil pressure exceeds the set point - When the oil pressure in the cylinder line rises above the pressure set by the spring, the poppet is moved to the left and opens the port. Then the oil in the chamber A flows to the tank through clearance between the body and sleeve. As a result, the pressure in the chamber A rapidly lowers and the plunger is moved to the left. Then the plunger opens the port to the tank port and the pressurized oil in the pump port escapes to the tank port.

65ZV-2 US 42-33 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T) Note Clogging of the orifice in plunger will cause low pressure. Another possible cause of low pressure is contamination in, or damage to, the seat of relief poppet, plunger, or clogging of the filter. Always clean the filter during overhaul of the relief valve.

Adjusting set pressure Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure. After adjustment, be sure to tighten the lock nut. Set pressure 20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi)

IMPORTANT Always be certain to tighten lock nut when finished with adjustment. Only set pressures in accordance with setting specifications.

65ZV-2 US 42-34 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T)

Multiple control valve overload relief valve (with make-up function) (Installed on both the rod and bottom sides of the bucket circuit) Each overload relief valve (with make-up function) is installed in the circuit between the cylinder and the control valve spool. When the spool is in the NEUTRAL position, if external force on the cylinder becomes too high and the oil pressure will be greatly increased, the overload relief valve returns the oil to the tank to protect the cylinders and pipes from breakage.

Overload relief valve operation 1. As overload relief valve Chamber B To tank

Sleeve Filter

Cylinder

Piston

Plunger

Poppet

Spring

65V2E42001

- When the oil pressure is at the set point or below: The pressurized oil from the cylinder is sent to the chamber B through the hole A of the piston, and the plunger is pressed against the sleeve by the spring force. Also the sleeve completely closes the cylinder port by the pressure area difference of the sleeve between the cylinder port side and the chamber B side. Sleeve To tank

Spring

Cylinder

Piston

Plunger

Chamber B Poppet

Spring 65V2E42002

- When the oil pressure exceeds the set point: When the oil pressure in the cylinder line rises above the pressure set by the spring, the poppet is moved to the right and opens the port. Then the oil in the chamber B flows to the tank through clearance between the body and sleeve. As a result, the pressure in the chamber B rapidly lowers and the plunger is moved right. Then the plunger opens the port to the tank port and the pressurized oil in the cylinder port escapes to the tank port.

65ZV-2 US 42-35 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T)

Adjusting set pressure

2. As make-up valve

From tank

Sleeve

Chamber B

Sleeve

Adjusting screw

To tank

Cylinder

65V2E42003

When the overload relief valve on one side of the cylinder port is actuated, the plunger in the control valve is in neutral. The port opposite to the one in which high pressure was produced has a greatly reduced pressure. When the pressure is reduced below the tank pressure, the make-up valve is opened. When the pressure at the cylinder port becomes less than tank pressure, the sleeve is moved to the right by the pressure area difference of the sleeve between the right and left (Y-X). The sleeve opens the port and the oil flows to the cylinder port. It prevents a vacuum (negative pressure) in the cylinder.

Lock nut Piston

Plunger

Poppet

Spring 70ZV42015

Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure. After adjustment, be sure to tighten the lock nut. Set pressure 23.5±0.5 MPa (240±5 kgf/cm2) (3,413±71 psi)

65ZV-2 US 42-36 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T)

Multiple control valve make-up valve (Installed on the rod side of the boom circuit) The make-up valve is installed in the circuit between the control spool and boom cylinder. Extremely quick boom lowering may generate low pressure due to low oil supply speed compared with boom lowering speed. The low pressure could form a vacuum that may cause cavitation. The purpose of the make-up valve is to prevent generation of such a vacuum. When the pressure in the rod side is lower than tank pressure, the make-up valve is opened to feed oil from the tank to the cylinder.

Make-up valve operation The make-up valve has the same structure as the overload relief valve with make-up valve does. Refer to the description on "Overload relief valve operation" for the makeup valve operation.

65ZV-2 US 42-37 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T)

Multiple control valve bucket spool Bucket spool operation 1. "Bucket Roll Back" position

D A1

Pa1

Pb1

From pilot valve

C From pump 65ZV42014

- When the control lever is set to the "Bucket Roll Back" position, the pilot pressure is applied on right oil pack (Pb1), the spool moves to the left, and spool shoulder (C) closes the center bypass line. As a result, the oil from the pump opens load check valve (D), flows from the B1 port into the bottom side of the bucket cylinder, and finally rolls back the bucket. - On the other hand, the oil on the rod side of the bucket cylinder returns from the A1 port to the tank.

65ZV-2 US 42-38 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T) 2. "Bucket Dump" position

D E A1

From pilot valve

Pa1

Pb1

C From pump 65ZV42015

- When the control lever is set to the "Bucket Dump" position, the pilot pressure is applied on left oil pack (Pa1), the spool moves to the right, and spool shoulder (C) closes the center bypass line. As a result, the oil from the pump opens load check valve (D), flows from the A1 port into the rod side of the bucket cylinder, and finally dumps the bucket. - On the other hand, the oil on the bottom side of the bucket cylinder returns from the B1 port to the tank. - Extremely quick dumping generates negative pressure (or a void) on the rod side. To prevent generation of negative pressure (or a void), make-up valve (E) of the overload relief valve opens so that the oil in the tank port flows into the rod side of the cylinder.

65ZV-2 US 42-39 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T)

Multiple control valve boom spool Boom spool operation 1. "Boom Raise" position

D A2

Pa2

Pb2

From pilot valve

C From pump 65ZV42016

- When the control lever is set to the "Boom Raise" position, the pilot pressure is applied on right oil pack (Pb2), the spool moves to the left, and spool shoulder (C) closes the center bypass line. As a result, the oil from the pump opens load check valve (D), flows from the B2 port into the bottom side of the boom cylinder, and finally raises the boom. - On the other hand, the oil on the rod side of the boom cylinder returns from the A2 port to the tank.

65ZV-2 US 42-40 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T) 2. "Boom Down" position

D E A2

From pilot valve

Pa2

Pb2

C From pump 65ZV42017

- When the control lever is set to the "Boom Down" position, the pilot pressure is applied on left oil pack (Pa2), the spool moves to the right, and spool shoulder (C) closes the center bypass line. As a result, the oil from the pump opens load check valve (D), flows from the A2 port into the rod side of the boom cylinder, and finally moves down the boom. - On the other hand, the oil on the bottom side of the boom cylinder returns from the B2 port to the tank. - Extremely quick lowering of the boom while the engine (pump) revolution is low generates negative pressure (or a void) on the rod side of the cylinder. To prevent generation of negative pressure (or a void), make-up valve (E) of the overload relief valve opens so that the oil in the tank port flows into the rod side of the cylinder.

65ZV-2 US 42-41 42 Function & Structure Hydraulic Group Multiple Control Valve (KML22/2T) 3. "Boom Float" position

From pilot valve

Pa2

Pb2

From pump

65ZV42018

- When the control lever is pushed downward beyond the "Boom Down" position to the "Boom Float" position, the spool moves fully to the right by the pressure oil from the Pa2. - As a result of this, all ports (i.e., pump port, cylinder rod end port and cylinder bottom end port) are connected to the tank port. - Therefore, the boom cylinder piston is not held by the oil pressure force any more and can move freely up and down by external force, which is useful for leveling uneven ground. Note Low pilot pressure can cause the boom circuit to "power down" when in float.

65ZV-2 US 42-42 42 Function & Structure Hydraulic Group Adapter (Orifice)

Adapter (Orifice)

1.0 Orifice

Orifice Installation position

65ZV42019

The adapter is installed in the boom lowering line between the pilot valve and the multiple control valve. When the lever is shifted back to the holding position just after lowering the boom, the boom spool of the multiple control valve is quickly returned to the holding position by the return spring. At this time, the boom lowering inertia causes a shock to the machine body. To lessen this shock to the machine body, the adapter (orifice) controls the spool return speed by slowly returning the pilot oil which was pushing the spool.

Note When the oil is very cold it will pass very slowly through the orifice. As a result it will take longer than normal for the spool to shift to neutral or holding position. Always warm up the oil before beginning normal operation.

65ZV-2 US 42-43 42 Function & Structure Hydraulic Group Ride Control (OPT)

Ride Control (OPT) Multiple control valve

To boom cylinder

K65V2U42005

1. Valve assembly (for ride control) 2. Accumulator (for ride control)

65ZV-2 US 42-44 42 Function & Structure Hydraulic Group Ride Control (OPT)

Ride control hydraulic circuit 3 2

Capacity 4.5 L Gas charging pressure: 1.96±0.1 MPa (20±1 kgf/cm2) (284.2±14.5 psi)

1 SP1

From multiple control valve

B (16) (17) (18)

(11)

(15) (13)

(14) Pilot lamp

F13 Ride control switch

MCU

SP2 (G3/4)

Hydraulic circuit Electrical circuit

1. Valve assembly (11) Charge switching spool (12) Reducing valve (13) Check valve (14) Solenoid valve (15) Flow control spool (16) Main spool (17) Orifice (18) Depressure valve (for accumulator circuit) 2. Accumulator 3. Boom cylinder

(12) 7.4±0.3 MPa (75±3 kgf/cm2) (1,073±43 psi)

From MCV pump port To MCV tank port

85V2E42013

Ride control function Ride control reduces fore and aft pitching motion to the machine in roading by using the boom cylinder and hydraulic circuit with the accumulator. Ride control can be operated or released by turning the ride control switch ON/OFF. Turn the ride control switch ON, and when the machine travelling speed reaches more than 7 km/h (4.3 mph), solenoid valve (14) comes to ON by a signal from the MCU, then the ride control works. When the machine travelling speed goes down to 5 km/ h (3.1 mph) or slower, no signal transferred from the MCU, as a result, the ride control does not work.

65ZV-2 US 42-45 42 Function & Structure Hydraulic Group Ride Control (OPT)

Ride control operation Preparation mode (ride control switch is OFF) 3 2

Capacity: 4.5 L Gas charging pressure: 1.96±0.1 MPa (20±1 kgf/cm2) (284.2±14.5 psi)

1 SP1

From multiple control valve

B (16) (17) (18)

(11)

(15) (13)

(14) Pilot lamp

F13 Ride control switch

MCU

SP2 (G3/4)

Hydraulic circuit Electrical circuit

The oil from the pump is reduced to 7.4 MPa (75 kgf/ cm2) (1,073 psi) by reducing valve (12) through charge switching spool (11). The oil flows into accumulator (2) through check valve (13), and also flows into the lower part of main spool (16) through solenoid valve (14), flow control spool (15) and orifice (17). Although the accumulator pressure applies to the upper part of main spool (16), the main spool is being kept by spring force at the lower part. In this condition, the ride control does not work because the both ports of the boom cylinder are closed.

(12) 7.4±0.3 MPa (75±3 kgf/cm2) (1,073±43 psi)

From MCV pump port To MCV tank port

85V2E42013

65ZV-2 US 42-46 42 Function & Structure Hydraulic Group Ride Control (OPT)

Running mode (ride control switch is ON) 3 2

Capacity: 4.5 L Gas charging pressure: 1.96±0.1 MPa (20±1 kgf/cm2) (284.2±14.5 psi)

1 SP1

From multiple control valve

B (16) (17) (18) (15)

(11)

(13) P

(14) Pilot lamp

F13 Ride control switch

Hydraulic circuit

MCU

SP2 (G3/4)

(12) 7.4±0.3 MPa (75±3 kgf/cm2) (1,073±43 psi)

Running mode

Electrical circuit

The ride control switch is ON, and when the machine travelling speed reaches more than 7 km/h (4.3 mph) solenoid valve (14) comes to ON by a signal from the MCU. When solenoid valve (14) is switched, the accumulator pressure applies to the upper part of charge switching spool (11) and the pump port is closed by pressing the spool down. Pressurized oil in the lower part of main spool (16) is drained to the tank through solenoid valve (14). As a result, main spool (16) is switched by the accumulator pressure, and the hydraulic line between the boom cylinder bottom side and the accumulator is connected. Then the accumulator absorbs the oil pressure fluctuations in the boom cylinder bottom side. On the other hand, the hydraulic line between the boom cylinder rod side and tank port is connected.

From MCV pump port To MCV tank port

85V2U42005

Flow control spool (15) and orifice (17) control the switching speed of main spool (16), and reduce the momentary motion of the boom cylinder by switching the main spool when there is pressure difference in the hydraulic circuit between the accumulator and boom cylinder bottom side.

65ZV-2 US 42-47 42 Function & Structure Hydraulic Group Ride Control (OPT)

Ride control valve assembly Outline drawing

(14)

From pump

(11)

(14)

(12)

KAYABA INDUSTRY CO,LTD TOKYO JAPAN

(18) B

To accumulator

(14)

SP2

SP1

(18) A

(13)

(15)(16) Boom cylinder bottom side

Boom cylinder rod side

A (15)(16)

(14)

65ZVE42018

1. Ride control valve assembly (11) Charge switching spool installation section (12) Reducing valve installation section (13) Check valve installation section (14) Solenoid valve (15) Flow control spool installation section (16) Main spool installation section (18) Depressure valve (for accumulator circuit)

65ZV-2 US 42-48 42 Function & Structure Hydraulic Group Ride Control (OPT) Section drawing

(11) P

(12) 1 21

(14)

22 23 (18) To accumulator

SP1

SP2

(13) (17)

(13)

B-B (15) (16)

A-A

Preparation mode K85V2E42001

1. Ride control valve (11) Charge switching spool (12) Reducing valve (13) Check valve (14) Solenoid valve (15) Flow control spool (16) Main spool (17) Orifice (18) Depressure valve (for accumulator circuit) 2. — 3. — 4. — 5. — 6. — 7. — 8. —

9. — 10. — 11. — 12. — 13. — 14. — 15. — 16. — 17. — 18. — 19. — 20. — 21. Lock nut 22. Adjusting screw 23. Lock nut

65ZV-2 US 42-49 42 Function & Structure Hydraulic Group Ride Control (OPT)

(11) P

(12) 1 21 (14) 22 23 To accumulator

SP1

SP2

(18) (13) (17)

(13) (15)

B-B

(16)

A-A

Running mode K85V2E42002

65ZV-2 US 42-50 42 Function & Structure Hydraulic Group Ride Control (OPT)

Solenoid valve

(ACC)

4 1

A 5

B Z Capacity 4.5 L Gas charging pressure: 1.96±0.1 MPa (20±1 kgf/cm2) (284.2±14.5 psi) SP1

P A

Viewed from Z

7.4±0.3 MPa (75±3 kgf/cm2) (1,073±43 psi)

From pump To tank 65ZVE42020

1. Body 2. Spool 3. Solenoid 4. Push rod 5. Pin

Specification Voltage

DC 24 V

Current

Resistance

24 

65ZV-2 US 42-51 42 Function & Structure Hydraulic Group Ride Control (OPT)

(ACC)

4 1

B 5

P A

T Viewed from Z

When push rod (4) is pushed manually K80V2J42011

WARNING When push rod (4) of the solenoid valve is pushed manually, even if no ride control switch is ON, the ride control hydraulic circuit changes to the running mode. As a result, the boom will go down if raised. It may cause serious injury or death. Before pushing push rod (4), it is necessary to put the machine on the level ground and lower the attachment on the level ground.

65ZV-2 US 42-52 42 Function & Structure Hydraulic Group Ride Control (OPT)

Accumulator (for ride control)

7 2

3 13 10

12 11 5 8 9 6

95ZV52058

1. Body 2. Hydraulic cap 3. Gas cap 4. Piston 5. V-O ring 6. Back-up ring 7. Wear ring 8. O-ring 9. Back-up ring 10. Gas valve 11. Gas valve O ring 12. Gas valve guard 13. Bolt

Accumulator function While the ride control operates, the accumulator absorbs fluctuation of the boom cylinder bottom pressure by air cushion function of the nitrogen gas charged in the cylinder. The cylinder contains N2 (Nitrogen) gas at 1.96 MPa (20 kgf/cm2) (284.2 psi). Accumulator specification Maximum operation pressure MPa (kgf/cm2) (psi) 2

20.6 (210) (2,986)

Nitrogen gas pressure MPa (kgf/cm ) (psi)

1.96 (20) (284.2)

Capacity (L)

4.5

65ZV-2 US 42-53 42 Function & Structure Hydraulic Group Steering System

Steering System A load sensing type steering system is employed, designed to save energy consumed in the hydraulic system (to raise the operational efficiency).

Accumulator

Orbitrol®

When the steering wheel is turned, an amount of oil proportional to the turning speed is sent from the pump to the steering cylinder through the priority valve and the Orbitrol®.

Orifice

Orifice Check valve

Steering cylinder

Accumulator

To loading circuit

Priority valve

When the steering wheel is not operated, almost all of the hydraulic oil discharged from the pump is supplied to the loading circuit. The priority valve detects the resistance of the hydraulic oil passing through the Orbitrol®, namely the speed of the steering wheel's rotation and the amount of oil, and then distributes oil to the loading and steering circuits. The accumulator is provided to prevent shock at the time of starting and stopping the steering wheel.

Pump

Tank K65V2E42004

65ZV-2 US 42-54 42 Function & Structure Hydraulic Group Steering System

3 3

1. Priority valve 2. Orbitrol® 3. Accumulator 4. Steering cylinder

(S/N 5001~5136)

(S/N 5137~)

K65V2U42011

65ZV-2 US 42-55 42 Function & Structure Hydraulic Group Priority Valve

Priority Valve To the steering line

To the loading line

EF 8

LS To the Orbitrol® LS port

7 To the tank

2 5

From the pump LS

A-A

Hydraulic symbols

1. Spool 2. Relief valve assy 3. Poppet 4. Screen 5. Spring 6. Adjusting screw 7. Orifice 8. Orifice 9. Spring

Model Maximum input pressure Rated flow

VLE61C210DPB 20.6 MPa (210 kgf/cm2) (2,986 psi) 150 L/min

Control pressure

1.0 MPa (10.3 kgf/cm2) (142 psi)

Steering relief pressure

20.6 MPa (210 kgf/cm2) (2,986 psi)

70V2U42001

65ZV-2 US 42-56 42 Function & Structure Hydraulic Group Priority Valve

Priority valve operation

To loading circuit

EF Spring Chamber B

T Pressure chamber A Spool

P Main steering relief valve

P: Pump T: Tank CO: Controlled orifice LS: Line signal CF: Controlled flow EF: Excess flow

From pump 70V2U42002

The priority valve functions to distribute oil discharged from only one pump adequately to both steering and loading circuits plus relieve excessive hydraulic pressure for steering.

1. When the steering wheel is not operated - Spool moves right and left depending upon the difference in the pressure between the pressure chambers A and B and the force of the spring. - When the steering wheel is not operated, the oil discharged from the pump flows into the Orbitrol® port P through the priority valve ports P and CF. - When the Orbitrol® is in the neutral state, P and T ports in the Orbitrol® are nearly closed (indicated by

orifice Co). So, in the CF circuit and also in the pressure chamber A the pressure will increase. - On the other hand, only a small amount of the pressure remains in the pressure chamber B, because it is connected to the tank through the Orbitrol® ports LS and T. - Accordingly, when a large difference in the pressure arises between the pressure chambers A and B, the spool moves from the left to the right and is held in that position. Now the EF circuit is almost fully opened and the CF circuit is only slightly opened. - The pressure in the steering circuit is equal to the spring force, namely about 1.0 MPa (10.3 kgf/cm2) (142 psi) regardless of the pressure in the loading circuit.

65ZV-2 US 42-57 42 Function & Structure Hydraulic Group Priority Valve

2. When the steering wheel is operated

To loading circuit

EF Pressure chamber B

T Pressure chamber A

P: Pump T: Tank C1: Controlled orifice LS: Line signal CF: Controlled flow EF: Excess flow

From pump 70V2U42003

- When the steering wheel is turned clockwise, the oil passage is changed in the Orbitrol® as shown above. Oil supplied to the Orbitrol® flows into the cylinder through control orifice C1 and the rotor. - There is the following relation among the passing resistance of the orifice C1 in the Orbitrol®, the angular displacement of the Orbitrol® spool and sleeve and the oil flow from the pump. - If the passing resistance is large, the difference in the pressure between the pressure chambers A and B becomes large, thus moving the spool to the right and decreasing the amount of oil supplied to the Orbitrol®. On the contrary, if the passing resistance is

small, the spool moves to the left and increasing the amount of oil supplied to the Orbitrol®. - So, the spool housed in the priority valve always works to keep the amount of oil discharged from the pump adequate to the speed of turning the steering wheel. Flow

Angular displacement

Passing resistance

Large

Medium

Large

Small

Large

Small

Large

Small

Medium

Note Larger angular displacement means that the turning speed of steering wheel is higher.

65ZV-2 US 42-58 42 Function & Structure Hydraulic Group Priority Valve

Operation of relief valve

To Orbitrol® P port

To loading circuit

Pressure chamber B

C2 Orifice

P: Pump T: Tank C1: Controlled orifice LS: Line signal CF: Controlled flow EF: Excess flow

LS From Orbitrol® LS port

T Pressure chamber A

P Relief valve From pump

Adjusting screw

70V2U42004

- When the steering cylinder reaches the stroke end, the pressure rises up to the set value of the relief valve 20.6 MPa (210 kgf/cm2) (2,952 psi) in the CF and LS circuits, and the relief valve comes into the action to relieve the high oil pressure. - At that time there is a difference in the oil pressure between the pressure chambers A and B. So, the spool moves to the right and nearly blocks the flow of the oil to the Orbitrol®. As oil is gradually fed into the chamber B through the orifice C2, the spool can move quickly to the right as soon as the relief valve has opened. - The steering main relief valve set pressure can be adjusted by tightening or loosening the adjusting screw inside the relief valve cartridge with an Allen wrench. Note Actual adjustment procedure is shown in the check and adjustment section of this manual.

65ZV-2 US 42-59 42 Function & Structure Hydraulic Group Orbitrol®

Orbitrol® A sensing-type Orbitrol® is used in this model in combination with the priority valve, which regulated the oil flow from the pump in proportion to the rotating speed of the steering wheel.

Valve System

Orbitrol® structure 1. Spool 2. Sleeve 3. Stator 4. Rotor 5. Drive shaft

6. Centering spring 7. Cross pin 8. Emergency check valve 9. Inlet check valve

As for the valve system of the Orbitrol®, load-sensing, non-load reaction, dynamic signal and Q/Amp. is adopted.

1. Load-sensing system Regardless of the load change, this system make it possible to steer with the compensated pressure and all amount of pump flow except the necessity for steering can be utilized for other actuators.

2. Non-load reaction system The L&R ports are blocked when the steering wheel is in neutral. This system is superior because reactive force of road surface does not transmit to the steering wheel. It’s effective for the operators to lighten the fatigue.

3. Dynamic signal

6 7

L Valve part

2 1

3 4

Rotor part

The signal of spool control of the priority valve is not only from Orbitrol® but also from priority valve directly, so the response of the steering is superior. 4

4. Q/Amp. Q: flow quantity Amp: amplification The Orbitrol® have the function to amplify the flow quantity. Flow quantity is changed depending on the rotation amount of the steering wheel. If the rotating speed is faster, discharge flow quantity is amplified. (Amplification ratio……2.0:1.0)

70V2E42010

65ZV-2 US 42-60 42 Function & Structure Hydraulic Group Orbitrol®

Orbitrol® specification

Valve part - The valve unit is a rotary directional selection valve, comprised of spool (1) and sleeve (2). The directional selection is achieved by turning the steering wheel, which is splined to spool (1). - When the steering wheel is not being turned, spool (1) and sleeve (2) are maintained in the central position by centering spring (6). The oil grooves in the spool and the oil holes in the sleeve are misaligned and the oil flow is completely cut off. - As the steering wheel is turned, the oil grooves in the spool and the oil holes in the sleeve align, the circuit opens and oil starts flowing to the steering cylinder.

Rotor part 1

Oil groove To tank To steering cylinder Oil hole

To steering cylinder

From priority valve (pump) To priority valve LS port

60ZV42038

- This is a type of internal gear which acts as a hydraulic motor when the valve unit is opened. - Rotation of rotor (4) is transmitted to the valve through connected drive shaft (5). This controls the opening of the valve according to the rate at which the steering wheel is turned.

Model

LPAWQKE

Theoretical delivery (cm3/rev)

369

Q/Amp Amplification ratio

2.0:1.0

Operation pressure MPa (kgf/cm2) (psi)

20.6 (210) (2,986)

Overload relief pressure MPa (kgf/cm2) (psi)

23.5 (240) (3,406)

65ZV-2 US 42-61 42 Function & Structure Hydraulic Group Orbitrol®

Orbitrol® operation

6 1 T

2 8

L Oil hole

Oil groove

6 7 1 2

Neutral

6 1 T

From priority valve CF port

3 Oil hole

Oil groove Amplified flow Turn

The flow of oil: The flow when the steering wheel is turned left

Turn When the rotating speed is increased

K65V2E42005

Neutral (When the steering wheel is not being turned) - Spool (1) and sleeve (2) of the valve part each have a slit into which centering spring (6) consisting of plate springs is set. - When the steering wheel is not being turned, spool (1) and sleeve (2) are kept in the neutral position by means of center spring (6). - This model is a load-sensing, non-load reaction, normally close type Orbitrol®. That is to say that, when

the valve unit is in the central position, the oil grooves in the spool and the oil holes in the sleeve are misaligned so that the oil flow from the pump to the steering cylinder is completely cut off. - When in the neutral position, the valve part is totally closed and oil remains sealed inside the rotor part, and the rotor cannot move. Sleeve (2) is directly linked to the rotor by means of cross pin (7) and drive shaft (5); it is also fixed.

65ZV-2 US 42-62 42 Function & Structure Hydraulic Group Orbitrol®

Turn (When the steering wheel is being turned) - When the steering wheel begins to be turned, rotary force is applied to spool (1), which then pushes and compresses centering spring (6) set in the slit; the oil groove of the spool matches the oil hole of the sleeve, and opens the hydraulic circuit. - As a result, all four ports (pump, tank and oil pack on right and left side of steering cylinder) are opened, allowing the oil to flow and rotating the rotor. - The pressure in the circuit up to the priority valve LS port also rises, increasing the volume of oil supplied to the Orbitrol®.

65ZV-2 US 42-63 42 Function & Structure Hydraulic Group Orbitrol®

Orbitrol® feed-back mechanism operation

Spool

Sleeve

Cross pin

Drive shaft Steering cylinder

Steering cylinder

Stator

Rotor

K80V2J42003

- When an angle of displacement (deviation in circumferential direction) is generated between the spool and the sleeve through operation of the steering wheel, the hydraulic circuit is opened, and oil starts flowing. Then the pressure to the priority valve LS port rise and the oil amount of supply to the Orbitrol® increase. Oil from the pump enters the Orbitrol® and turns the rotor; this oil flows into the steering cylinder. At this time, the rotor rotation is transmitted to the sleeve by the drive shaft and the cross pin. - As a result, the sleeve starts rotating slightly behind the spool as if to follow its rotation. This way the

spool can continue rotating, allowing the steering wheel to be turned and the machine to be turned. - If the turning of the steering wheel stops, the spool immediately stops rotating; but, as long as there exists an angle of displacement between the spool and the sleeve, oil continues flowing into the Orbitrol®, and the rotor can continue rotating. Due to this rotation, the sleeve catches up with the spool, and closes the hydraulic circuit. Finally, the centering spring returns the spool and the sleeve to the neutral position and flow of oil is completely stopped. Then the pressure to the LS port drop and the oil amount of supply to the Orbitrol® decrease.

65ZV-2 US 42-64 42 Function & Structure Hydraulic Group Orbitrol®

Steering speed and flow rate control Low steering speed

- When there is plenty of oil flowing from the pump, the force required to turn the steering wheel need only overcome the sliding resistance of the sleeve or rotor, so the steering wheel turns very smoothly.

High steering speed

1 3 Small displacement angle

Large displacement angle

Hydraulic pump oil amount and steering force

70ZV42028

1. Spool 2. Sleeve 3. Centering spring - For this steering mechanism, the flow rate must be regulated depending on the speed at which the steering wheel is turned. - For the steering valve, the flow rate is regulated by changing the displacement angle of spool (1) and sleeve (2). In other words, while the steering wheel is being turned, sleeve (2) chases spool (1) in rotation, trying to close the hydraulic circuit. - As steering speed increases, the amount of delay (displacement angle) of sleeve (2) increases, and the flow rate rises.

- When the amount of oil from the pump is small, the displacement angle of the spool and sleeve reaches a maximum point; even if the hydraulic circuit is wide open, the flow of oil from the pump to the rotor is small, so the rotor turns slowly. - For this reason, the spool rotates faster than the rotor, and the displacement angle reaches a maximum point, and the spool turns the rotor by means of the cross pin and drive shaft. At that time, the rotor works as a hydraulic pump, and the steering wheel is harder to turn.

65ZV-2 US 42-65 42 Function & Structure Hydraulic Group Orbitrol®

Oil flow change when Q/Amp. is operated - When the rotating speed of steering wheel is 10 min-1 or less at the low rotation zone as we say, the discharge of this Orbitrol® is largely similar to conventional one. But when the rotating speed exceeds 10 min-1 until 60 min-1, the oil flow is amplified in proportion to the rotating speed of the steering wheel.

(L/min)

Flow quantity discharged from steering pump

- When it exceeds 60 min-1 at the high rotation zone as we say, the flow is amplified and increase to twice its amount.

high rotation zone

amplified flow

low rotation zone

Flow line controlled by rotor

60 10 Rotating speed of steering wheel

min -1 (r.p.m) 70V2E42012

65ZV-2 US 42-66 42 Function & Structure Hydraulic Group Orbitrol®

Orbit rotor operation principle Drive shaft (0 rotation) Rotor center

Drive shaft (1/14 rotation)

Drive shaft (1/7 rotation)

Rotor (rotation) Stator (fixed)

Locus of star center

1 7

1 2

:Flow of high-pressure oil :Flow of low-pressure oil

- Inside the rotor there is a stator with 7 internal gears that is fixed to the housing and a 6-teeth rotor that is engaged with the stator. - Half of the chamber formed by the stator and the rotor is connected to the high-pressure side and the other half to the low-pressure side. When high-pressure oil flows into the chamber, the rotor is forced to turn in the direction that will expand the area of the chamber (by means of pressure difference). - When overrunning the power assist capacity of the rotor due to very fast rotation or turning the steering wheel vigorously, rotation of the sleeve and spool takes place by means of the cross pin. - With this rotation, and at the same time due to the relationship of the position between the sleeve port and the housing port, the position of oil flowing into the rotor part is gradually delayed in sequence.

70ZV42029

- The rotor makes a 1/6 turn per rotation of the rotor, pushing out oil equivalent to 7 chambers. When the rotor rotates once, oil equivalent to 42 chambers (7 chambers x 6 turns) is pushed out. - For the motor, it has 6 times larger torque or a 1/6 reduction effect.

65ZV-2 US 42-67 42 Function & Structure Hydraulic Group Orbitrol®

Auxiliary valves

1 A E 4 3

1. Overload relief valve (section E-E)

2. Make-up valve (section D-D)

A–A 3. Emergency check valve

4. Inlet check valve (#4)

D D D

The Orbitrol® housing contains two overload relief valves, two make-up valves, one inlet check valve, and one emergency check valve. LS port To priority valve

65V2E42004

65ZV-2 US 42-68 42 Function & Structure Hydraulic Group Orbitrol®

Overload relief valve and make-up valve

If the external force is applied to the steering cylinder under this condition, the high pressure would be created in the circuit, and the pressurized oil might cause a ruptured pipe or cylinder, a bent piston rod, or some other problem, unless the oil is allowed to escape.

Cylinder port Tank port

Poppet

When the steering wheel is not being turned, the oil between the Orbitrol® and the cylinder is sealed in.

Adjusting screw

The overload relief valve directs this pressurized oil to the tank. (Relief pressure setting = 23.5 MPa (240 kgf/ cm2) (3,406 psi) The set pressure of the overload relief valve can be adjusted by turning the adjusting screw.

External force

Make-up valve

Overload relief valve

Note Unless the Orbitrol® is removed, it is impossible to adjust the overload relief valve.

Orbitrol®

Tank port

When the overload relief valve opens and causes the oil in the cylinder to escape to the tank, the pressure in the opposite section of the cylinder (the rod end of the cylinder in the figure) becomes negative. When that happens, the make-up valve opens and directs the oil from the tank into the cylinder, cancelling the suction pressure in the cylinder.

Check ball

Cylinder port

70V2E42014

65ZV-2 US 42-69 42 Function & Structure Hydraulic Group Orbitrol®

Emergency check valve In the event that the pump fails to supply oil to the steering system, this valve functions so that the steering wheel can still be turned. Normally, the check ball is pressed to the extreme left by oil introduced through the pump port, blocking the tank port. T

When the steering wheel is turned while no oil is supplied from the pump due to engine failure or the like, the Orbitrol® serves as a pump, sucking in oil through the tank port and sending it to the steering system. Thus, the steering wheel can be turned even through no oil is being supplied from the regular pump.

Tank port

Emergency check valve Pump port Inlet check valve

Inlet check valve

LS Emergency check valve

When the steering wheel is turned and the cylinder reaches its stroke end, the relief valve in the priority valve is actuated. Normally, when the steering wheel is released under this condition, the hydraulic circuit would return to neutral, and oil under high pressure might remain in the circuit. If the steering wheel is turned slowly in the same direction again, the high oil pressure remaining in the circuit would flow back through the pump port. As a result, oil from the Orbitrol® would turn the steering wheel in the direction opposite to that in which it is being turned. (Note, however, that this phenomenon would not occur if the steering wheel was being turned in the opposite direction.)

To prevent this reverse flow of oil, the inlet check valve is installed between the priority valve and the Orbitrol®. 70V2E42015

65ZV-2 US 42-70 42 Function & Structure Hydraulic Group Accumulator

Accumulator

(S/N 5137~)

(S/N 5001~5136)

K65V2U42012

1. Accumulator

65ZV-2 US 42-71 42 Function & Structure Hydraulic Group Accumulator

Accumulator

Cap

K65DV2J42009

The accumulator is provided between the Orbitrol® and each of the steering cylinder to prevent the pressure surges in the circuits from causing shocks to the machine when turning of the steering wheel starts and stops. Nitrogen gas at 5.0 MPa (50 kgf/cm2) (710 psi) is charged in the gas chamber. Accumulator specifications Maximum operating pressure MPa (kgf/cm2) (psi)

20.6 (210) (2,985)

Nitrogen gas charging pressure MPa (kgf/cm2) (psi)

5.0±0.1 (50±1) (710±14)

Nitrogen gas capacity L (gal)

0.2 (0.05)

WARNING Never weld on or near gas charged accumulator. Serious injury may result.

65ZV-2 US 42-72 42 Function & Structure Hydraulic Group Efficient Loading System (OPT)

Efficient Loading System (OPT) Efficient loading system outline

Efficient loading system (it is assumed ELS as follows) improves the performance of excavating and scooping when operating, and drastically shortens the cycle time. When the ELS switch at the instrument panel is turned on and excavating, more specifically, the ELS operation condition showing as follows is satisfied, the solenoid valve in the ELS valve is energized and all the hydraulic oil from the main pump goes to the hydraulic tank.

Fast

Therefore most of the engine power is applied to the wheels to exert maximum driving force by turning off the main pump and reducing the pump driving load on engine. Slow and higher driving force

In addition, as for the loading operation, it becomes easy to operate slightly by reducing the quantity of total oil to the loading circuit, and is improved the performance of operating when excavating and scooping.

When excavating and scooping Switch pump

Multiple control valve

Steering valve

Main pump

Boom Bucket

ELS valve

Fuel efficient mode switch is also installed at the instrument panel when operating at the time of fuel saving driving. If the combination of ELS switch and fuel efficient mode switch is selected properly, it can be able to improve the fuel consumption without reducing the operation efficiency. In addition, the height range of the boom that ELS operates can be set up to the arbitrary height depending on setting of the variable kickout sensor.

Hydraulic tank

When raising the boom Switch pump

Main pump

Multiple control valve

Steering valve

Boom Bucket

The operation condition of ELS The ELS switch ON

ELS valve

Hydraulic tank Concept of the ELS operation

85V2E42054

Shift lever

Forward position

Machine speed

Less than 5 km/h

Boom height

The setting position of the variable kickout sensor is less than it.

65ZV-2 US 42-73 42 Function & Structure Hydraulic Group Efficient Loading System (OPT)

Mounting of the ELS valve (S/N 5001~5100)

Multiple control valve P line

(PG1) (A)

(P)

From main pump

Priority valve EF line

Center pin

(PG2) (T)

To hydraulic tank 1

Hydraulic line

ELS valve

PG2

Axle center line PG1 (SEN)

T 1

Rear chassis 3

Detail of ELS valve section K65V2U42001

1. Solenoid valve 2. Relief valve Setting pressure 20.6 MPa (210 kgf/cm2) (2,987 psi) 3. Check valve Cracking pressure 0.2 MPa (2 kgf/cm2) (29 psi)

4. Pressure sensor

65ZV-2 US 42-74 42 Function & Structure Hydraulic Group Efficient Loading System (OPT) (S/N 5101~)

3 4 (PG1)

From main pump

(PG3)

(P)

Priority valve EF line

(A)

Center pin

Multiple control valve P line (PG2) (T)

ELS valve

To hydraulic tank

Hydraulic line

PG2

Axle center line PG1

PG3

Rear chassis 3

Detail of ELS valve section

K65V2U42013

1. Solenoid valve 2. Relief valve Setting pressure 20.6 MPa (210 kgf/cm2) (2,987 psi) 3. Check valve Cracking pressure 0.2 MPa (2 kgf/cm2) (29 psi) 4. Pressure sensor

65ZV-2 US 42-75 42 Function & Structure Hydraulic Group Efficient Loading System (OPT)

Mounting of the variable kickout sensor 5

8 2 3

Apply grease at area

1 Detail of grease applying

A Boom

5,8

When the boom is horizontal

Chassis

3 1,7 1

Detail of A 85V2E42056

1. The variable kickout sensor 2. Link 3. Plate 4. Plate 5. Shaft 6. Ball bearing 7. O-ring 8. Spring pin 9. Rod

65ZV-2 US 42-76 42 Function & Structure Hydraulic Group Efficient Loading System (OPT)

Efficient loading system operation While the ELS is not operating

The oil discharged from the switch pump flow into the priority valve P port. When the steering wheel is not turned, this oil is discharged from the priority valve EF port.

(S/N 5001~5100) 4

Multiple control valve P line

On the other hand, the oil discharged from the main pump opens the check valve, because cracking pressure of check valve (3) is less than the setting pressure of relief valve (2).

Priority valve EF line

From main pump

Cracking pressure of check valve (3) 0.2 MPa (2 kgf/cm2) (29 psi) Setting pressure of relief valve (2) 20.6 MPa (210 kgf/cm2) (2,987 psi) The oil from switch pump and main pump are joined together and flow into the multiple control valve P port.

1 80V2E42007

Therefore it can be able to operate the boom and bucket at normal speed.

(S/N 5101~) In addition, the pressure sensor is installed in the discharged side of the main pump and detects oil pressure of loading line and sends the signal to the MCU.

Priority valve EF line

From main pump

Multiple control valve P line

K70V2U42003

65ZV-2 US 42-77 42 Function & Structure Hydraulic Group Efficient Loading System (OPT)

While the ELS is operating

When the ELS switch is turned on and the ELS operation condition set by the MCU is satisfied, the solenoid valve in the ELS valve is energized and the spool is moved.

(S/N 5001~5100) 4

Multiple control valve P line

After that, the setting pressure of relief valve drops to the hydraulic tank pressure level.

Priority valve EF line

From main pump

Therefore, the oil discharged from the main pump opens relief valve (2) that setting value dropped and all the hydraulic oil from the main pump goes to the hydraulic tank. But the oil from the priority valve EF port cannot flow into relief valve (2) because of check valve (3), and flow into the multiple control valve P port.

To Hydraulic tank

1 80V2E42008

Therefore when the ELS is operated, most of the engine power is applied to the wheels to exert maximum driving force by turning off the main pump and reducing the pump driving load on engine.

(S/N 5101~) In addition, it becomes easy to operate slightly by reducing the quantity of total oil to the loading circuit, and is improved the performance of operating when excavating and scooping.

Priority valve EF line

From main pump

Multiple control valve P line

To Hydraulic tank

K70V2U42004

65ZV-2 US 42-78 42 Function & Structure Hydraulic Group Fan Motor System

Fan Motor System Mounting of fan motor

Engine

T1 L2 T2 L1

K65V2E42006

1. Fan motor 2. Fan : T1: 93.7 N-m (9.55 kgf-m) (69 lb-ft) T2: 117.3 N-m (11.5 kgf-m) (87 lb-ft) L1: Screw lock agent (Loctite® 262) L2: With lubrication oil (Engine oil or gear oil)

65ZV-2 US 42-79 42 Function & Structure Hydraulic Group Fan Motor Line

Fan Motor Line (S/N 5001~5158) Fan revolution (min-1)

Engine coolant: High temperature [94ºC (201.2ºF)]

1,600 Stepless control range

1,120

Middle range temperature [60~80ºC (160~180ºF)]

(456)

Low temperature [below 60ºC (160ºF)]

0 800

1,200

(1,512) Engine revolution (min-1)

(2,075) Values inside ( ) are offered as reference.

Fan revolution * (controlled by MCU) * To shorten the warm-up time, when the engine water temperature is 60ºC (140ºF) or less and the engine revolution is 1,200 min-1 or less, the fan revolution is kept minimum without reference to the engine revolution.

65V2E42005

(S/N 5159~) Fan revolution (min-1)

Engine coolant: High temperature [94ºC (201.2ºF)]

1,600 Stepless control range

1,120

Middle range temperature [60~80ºC (160~180ºF)]

(456)

Low temperature [below 60ºC (160ºF)]

0 800

(1,512) Engine revolution (min-1)

(2,075) Values inside ( ) are offered as reference.

Fan revolution * (controlled by MCU)

K65V2U42007

65ZV-2 US 42-80 42 Function & Structure Hydraulic Group Fan Motor Line

Fan motor (1)

Cooling fan

Flow control valve (2)

16.0 cm3/rev

Flow control solenoid (3)

MCU

D A C

To return filter

Fan motor assy Hydraulic circuit diagram

From unloader valve K65V2E42007

The cooling fan is driven by the hydraulic motor. The pressure oil from the unloader valve flows into the port P of fan motor assembly, enters fan motor (1) and flow control valve (2), and then, turns fan motor (1). Three kinds of signals sent from the ECM, torque converter oil temperature sensor, and hydraulic oil temperature sensor, are input into the MCU as information to regulate the maximum fan revolution. The fan revolution is regulated by the oil amount supplied to fan motor (1). Oil amount supplied to fan motor (1) is changed in proportion as the engine revolution and the opening area of flow control valve (2). The opening area is regulated by the pilot pressure to flow control valve (2) that is changed by electric current value from MCU to flow control solenoid (3).

65ZV-2 US 42-81 42 Function & Structure Hydraulic Group Fan Motor Line

Solenoid output current F for control of the fan revolution Fan revolution Flow control solenoid [mA] (min-1)

1,120

Flow control solenoid [mA]

About 480

F H/D F T/M F E/G

1,600

0 0 80 (176)

94 ( C) T E/G (201.2) ( F)

The signal of the engine coolant temperature

110 (230) T T/M

115 ( C) (239) ( F)

The signal of the torque converter oil temperature

90 (194) T H/D

95 ( C) (203) ( F)

The signal of the hydraulic oil temperature

Control of the fan revolution 65V2E42006

When the input electric current value to flow control solenoid (3) is maximum (approximately 480 mA), the fan revolution is minimum value (1,120 min-1) because bypass oil amount at flow control valve (2) is increased. When this value is minimum (0 mA), the fan revolution is maximum value (1,600 min-1) because bypass oil amount at flow control valve (2) is decreased. When the engine water temperature is low, the electric currents value from the MCU to flow control solenoid (3) is big. As a result, bypass oil amount from port P to the fan motor (1) line becomes big, and then the fan revolution becomes low. When the torque converter oil temperature is 110ºC (230ºF) or less and the hydraulic oil temperature is 90ºC (194ºF) or less, the fan revolution is controlled only by engine water temperature.

In normal condition, fan revolution is regulated by engine water temperature. But when the torque converter oil temperature exceeds 110ºC (230ºF) or the hydraulic oil temperature exceeds 90ºC (194ºF), in each signal input into a MCU from the engine water temperature, torque converter oil temperature and hydraulic oil temperature sensors, the lowest signal in the electric current value is chosen (the fan revolution becomes high to lift the cooling performance), and the control electric current is input into flow control solenoid (3).

65ZV-2 US 42-82 42 Function & Structure Hydraulic Group Fan Motor Line

Hydraulic circuit (fan motor normal rotation) Fan motor (4) Flow control solenoid (3)

Fan motor assy

MCU (Engine water temp. sensor T/C oil temp. sensor Hydraulic oil temp. sensor) Flow control valve (2)

Brake circuit

Safety valve (1)

Relief valve

Unloader valve

Hydraulic tank

Hydraulic circuit diagram

K80V2J42017

65ZV-2 US 42-83 42 Function & Structure Hydraulic Group Fan Motor Line

Safety valve (with suction function)

Flow control valve

Suction function

In this case, oil from the tank-return circuit is supplied to fan motor (4) inlet port through the safety valve to prevent cavitation. When the pressure oil from the hydraulic pump is supplied to the inlet port P, the pressure in the MA side circuit of the fan motor will increase. The starting torque for the fan motor is generated, and the motor starts to rotate. The oil in the MB side circuit of the fan motor returns to the hydraulic tank via the outlet port T. When engine stops, the pressurized oil from the pump is not supplied to fan motor (4) inlet port, as a result, the fan motor revolution speed gradually decreases. Oil supply is stopped, however the fan is still turning by the inertial force. This condition generates negative pressure at the motor inlet port. To prevent generation of negative pressure, the safety valve opens so that the oil in the tank port flows into the fan motor inlet port.

Safety function When starting engine, pump discharge pressure may rise extremely high. To prevent the fan motor line from damages, the relief valve is installed. If the pump discharge pressure exceeds the set pressure, the relief valve relieves the pressurized oil to the tank port.

B Fan motor revolution

If the oil pressure at fan motor (4) inlet port comes to negative pressure, cavitation may generate.

A C

Q0 Oil amount supplied to motor

Q1 85V2E42038

Flow control valve (2) supplies the pump discharge amount necessary to fan motor (4) and returns excess oil to the tank. Fan motor revolution rises in proportion to oil amount (Q) supplied to fan motor (4). When the amount of oil supplied to fan motor (4) is Q1, the fan rotates with B min-1. To reduce noise from fan and also energy loss, it is necessary to keep fan revolution constantly with necessary fan revolution, regardless of the oil amount supplied to the fan motor. Oil amount in A-B-C area returns to the tank. For this purpose, flow control valve (2) is installed in the line. Even when oil amount to the fan motor changes from Q0 to Q1, the fan revolution is kept from A to C min-1 constantly.

65ZV-2 US 42-84 42 Function & Structure Hydraulic Group Fan Motor Line

Flow control valve Proportional solenoid valve

Pump Throttle (D)

Command current

P Throttle section (E)

C A

Adjusting screw

Main spool (dummy)

Spring for flow control valve K70V2J42006

Fan motor revolution

Flow control solenoid valve

The regulated maximum number of revolutions varies depending on the input electric current value from the MCU to flow control solenoid (3). In this motor, upstream pressure of throttle is led to A side and downstream pressure is led to B side of flow control spool. When the pressurized oil from the pump flow into P port, the pressure difference generated before and after the throttle section works on the spring of the flow control spool.

C Stepless control range

A’

C’ High temp.

Low temp.

Oil amount supplied to motor 70V2U42006

Flow control solenoid valve (3) (proportional pressure solenoid) is used in the fan motor line. In addition three kinds of signals sent from the ECM, torque converter oil temperature sensor, and the hydraulic oil temperature sensor, are input into the MCU as information to change fan revolution.

When oil amount supplied to port P is Q0 or more in the figure, pressure difference (PA-PB) at the flow control spool grows bigger than installation load of it. After that, because flow control spool is opened (PT) to discharge excess oil to tank line (the shaded region shown in the figure), the fan revolution is kept from A to C min-1 constantly. The proportional flow control valve is installed on this motor. It is possible for this motor to change the fan revolutions from A-C to A’-C’ range consecutively by changing the command current as shown in figure.

65ZV-2 US 42-85 42 Function & Structure Hydraulic Group Fan Motor Line

Fan motor (S/N 5001~5054)

Port Tc

Port P

Port T

EF connector (Flow control sol.)

C Z

A K65V2E42008

Note For normal rotation only. Fan motor specifications Displacement capacity Rating Speed control

16±1 cm3/rev (1.0 in3/rev)

Pressure

14.2 MPa (145 kgf/cm2) (2,060 psi)

Speed

1,600 min-1

Flow

25.6 L/min (6.7 gal/min)

Control method

Continuous variable control with solenoid valve

65ZV-2 US 42-86 42 Function & Structure Hydraulic Group Fan Motor Line

Fan motor structure (S/N 5001~5054)

B-B

21 4

6 5

2 1

11 10

8 9

A-A

C-C K65V2U42008

1. Output shaft 2. Case 3. Thrust plate 4. Piston assy 5. Cylinder block 6. Valve plate 7. Retainer guide 8. Retainer shoe 9. Main bearing 10. Sub bearing 11. Oil seal

12. End cover 13. Center spring 14. Spring for safety valve 15. Safety valve with suction function 16. Variable flow control valve 17. Flow control spool 18. Spring 19. Main spool (dummy) 20. Flow control solenoid valve 21. Filter 22. Spacer

65ZV-2 US 42-87 42 Function & Structure Hydraulic Group Fan Motor Line

Fan motor (S/N 5055~) ER connector (Reversing sol.)

Port Tc

Port P

Port T EF connector (Flow control sol.) Z

C A

C Z

A K65V2E42009

Note For both normal and reverse rotation. Fan motor specifications Displacement capacity Rating Speed control

16±1 cm3/rev (1.0 in3/rev)

Pressure

14.2 MPa (145 kgf/cm2) (2,060 psi)

Speed

1,600 min-1

Flow

25.6 L/min (6.7 gal/min)

Control method

Continuous variable control with solenoid valve

65ZV-2 US 42-88 42 Function & Structure Hydraulic Group Fan Motor Line

Fan motor structure (S/N 5055~)

B-B

15 23

18 22 7

11 10

8 9

A-A

C-C K65V2U42009

1. Output shaft 2. Case 3. Thrust plate 4. Piston assy 5. Cylinder block 6. Valve plate 7. Retainer guide 8. Retainer shoe 9. Main bearing 10. Sub bearing 11. Oil seal 12. End cover

13. Center spring 14. Spring for safety valve 15. Safety valve with suction function 16. Variable flow control valve 17. Flow control spool 18. Spring 19. Main spool 20. Flow control solenoid valve 21. Filter 22. Selector valve (*) 23. Reversing solenoid (*) 24. Spring (*) (*) Optional parts for reversing fan motor

65ZV-2 US 42-89 42 Function & Structure Hydraulic Group Fan Motor Line

Fan motor function and the operation principle

This hydraulic motor is swash plate type axial piston motor. This converts the power of pressured oil sent from the hydraulic pump into rotary motion.

The oil sent from the hydraulic pump is led into cylinder block (5) through valve plate (6). This oil is led only onto a half of plate (6) separated by Y-Y line which links a bottom dead center to a top dead center at piston (4) process.

ri F3

The pressure a oil in a half of cylinder block, that is separated by Y-Y line, pushes each piston (4) (two or three), and then generates the force F1 (F1=P (kgf/cm2) x /4 x D2 (cm2)). Y

85V2E42043

This force pushes thrust plate (3) fixed at a certain angle  for output shaft (1), and it is divided into two component force F2 and F3.

Among the component forces, radial component force F3 generates the torque T (T=F3 x ri) at each piston (4) located at a half of plate (6) separated by Y-Y line linking a top dead center to a bottom dead center.

Resultant force of this torque (T= (F3 x ri)) goes through a piston as turning force and turns cylinder block (5).

85V2E42044

4 5

Supply side

3 Discharge side

85V2E42045

Because this cylinder block (5) is connected to the output shaft, the output shaft turns, and then torque is transmitted.

65ZV-2 US 42-90 42 Function & Structure Hydraulic Group Reversing Fan Motor Line

Reversing Fan Motor Line Reversing fan motor function Note This function has been a standard feature on S/N 65J4-5055 and thereafter.

If the fan turns in reverse direction under the following conditions, reverse control of fan is canceled. The reversal fan indicator lamp flashes at 0.5 sec cycle (ON: 0.25 sec, OFF: 0.25 sec) for 3 seconds, and then the lamp turns off and the fan turns in normal rotation.

Functional limitation conditions: When either one of the following temperature exceeds the preset upper limit(s), the cooling fan reverse rotation function does not work.

Switch

1. Signal of engine water temperature > 94ºC (201.2ºF) 2. Signal of torque converter oil temperature > 115ºC (239ºF) 65V2U42001

3. Signal of the hydraulic oil temperature > 95ºC (203ºF)

Engaging this switch reverses the rotation of the cooling fan for cleaning the radiator fins. When pushing this switch for more than 2 seconds with the engine running, the switch turns "ON", the pilot lamp on the switch lights up and the cooling fan turns in reverse rotation for 1 minute, after which it returns to it's normal rotation. The fan turns continuously in reverse direction for 1 minute at 30 minute intervals. When the switch is pushed again for more than 2 seconds, the cooling fan reversal switch turns "OFF" and the pilot lamp on the switch turns "OFF". Then the cooling fan turns in the normal direction. The cooling fan reversal switch can be operated any time the engine is running. It is not necessary to stop the machine to push the reversal cooling fan switch.

Reversing fan motor Refer to "Fan motor (S/N 5055~)" page 42-87 for the motor specification and structure.

65ZV-2 US 42-91 42 Function & Structure Hydraulic Group Reversing Fan Motor Line

Reversing fan control chart Reversing control

Normal control ON

Reversing solenoid valve

OFF

FVR1 Flow control solenoid valve output current Fv Flow control solenoid valve

FVR2

t FV1

t FV2

t AR2

t AR1

t AR2 ON

Reversing fan switch

OFF 2 sec Switching timing chart of reversing fan t: sec F: mA

t FV1

t FV2

t AR1

1,800

t AR2

F VR1

approx. 480

F VR2

85V2E42047

65ZV-2 US 42-92 42 Function & Structure Hydraulic Group Reversing Fan Motor Line

Hydraulic circuit (Reverse rotation) Fan motor (4)

Selector valve (6)

Fan motor assy

Flow control solenoid (3) MB

Reverse solenoid (5)

To MCU (Reversing cooling fan switch)

MCU (Engine water temp. sensor T/C oil temp. sensor Hydraulic oil temp. sensor)

Flow control valve (2)

Brake circuit

Safety valve (1)

Relief valve

Unloader valve

Hydraulic tank

Hydraulic line (reverse revolution)

K80V2J42018

When the cooling fan reversal switch is "ON", reverse solenoid valve (5) is magnetized. The solenoid valve spool moves to the left. Oil from the pump pushes selector valve (6) to the left. As a result, the fan motor turns into reverse.

65ZV-2 US 42-93 42 Function & Structure Hydraulic Group Secondary Steering (OPT)

Secondary Steering (OPT) (S/N ~5020) Pressure sensor Secondary steering motor and pump

Hydraulic pump

Magnetic switch

Check valve

(S/N ~5020)

Priority valve

Hydraulic tank

K65V2U42006

Speed sensor Pilot lamp

To priority valve

F13 MCU

To loading line Pressure sensor

Check valve

Check valve G1 G1/2

+24 V

Secondary steering motor and pump

G1 G1/2

10 cm3/rev

G3/8

11.7 MPa (119.3 kgf/cm2) (1,696 psi)

To brake and pilot line

45.6 26.7 14.2 cm3/rev cm3/rev cm3/rev G1/4 TS

Magnetic switch (on motor and pump) Steering pump

Hydraulic line Electrical circuit

Secondary steering circuit K65V2E42010

65ZV-2 US 42-94 42 Function & Structure Hydraulic Group Secondary Steering (OPT)

Secondary steering operation In normal operation, the oil from the steering pump flows into the priority valve through the check valve. And the signal of the pressure sensor is always sent to the MCU. With some problems, as the steering hydraulic pressure goes down while the engine is running, the pressure sensor signal becomes less than the preset value at the MCU more than 1 sec. In this condition, if the machine speed is more than 2 km/h, the MCU sends a signal to the magnetic switch. As a result, the secondary steering motor and pump is driven. Then it is ready to steer the machine. Pressure sensor preset value Steering hydraulic pressure ON: at 0.3 MPa (3 kgf/cm2) (44 psi) or lower OFF: at 0.4 MPa (4 kgf/cm2) (58 psi) or higher

The signal from MCU to magnetic switch

Machine speed signal

Machine speed

OFF

(km/h)

85V2E42051

65ZV-2 US 42-95 42 Function & Structure Hydraulic Group Secondary Steering (OPT)

Secondary steering motor and pump CW rotation

Magnetic switch

Relief valve

+24 V

Motor

+24 V

Pump

Customer's power connection

Relief valve 11.7 MPa (119.3 kgf/cm2)

Customer's MCU connection

Customer's ground connection Electric/Hydraulic schematic 80V2E42013

Secondary steering motor and pump Model

Haldex 11183G00

Discharge (cm3/rev)

Relief valve setting pressure MPa (kgf/cm2) (psi)

11.7 (119.3) (1,696)

85V2E42052

65ZV-2 US 42-96 42 Function & Structure Hydraulic Group

MEMO

65ZV-2 US 43-1 43 Check & Adjustment Hydraulic Group

43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ........................................................................... 43-2 Hydraulic Cylinder ................................................... 43-11

65ZV-2 US 43-2 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) Loading circuit relief valve setting pressures WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service man. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine

CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the access panel of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is stopped.

Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for loading line with 3 m (10 ft.) hose) 5 MPa (50 kgf/cm2) (1,000 psi) (for pilot line) with 2~3 m (6~10 ft.) hose

CAUTION Be careful, you may get burned if the high pressure oil spouts out. To prevent such an accident, be sure to release the residual pressure from the pipe, and open the cap of the hydraulic tank before removing the plug from the pressure measurement port.

Note For safety purpose, route the gauge to an area where it may be safely read by the person doing the test.

Standard measurement value Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground. Tilt down the bucket until it comes in contact with the ground. Place the bucket control lever in the roll back position, and then lower the boom. Push down on, then open the cap of the hydraulic tank to release the residual pressure.

Loading line main relief pressure (at maximum speed) MPa (kgf/cm2) (psi)

20.6±0.5 (210±5) (2,986±71)

Loading line overload relief pressure (at idling speed) MPa (kgf/cm2) (psi)

23.5±0.5 (240±5) (3,413±71)

Pilot line

MPa (kgf/cm2) (psi)

3.5 (36) (512)

Hydraulic oil temperature: 50±5ºC (120±9ºF)

65ZV-2 US 43-3 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Gauge port

Valve assembly Gauge port location

Port size

Main relief pressure (1), (2), (3)

(1) Rc (PT) 1/4

Overload relief pressure

(2), (3) G (PF) 1/4 with O-ring

(1), (2), (3)

(5) (PPI)

(Z2)

(4)

(Z)

(Z1)

(PA) (PARKING)

ACF

(ACCF)

(ACCR)

(TA)

Pilot line pressure (Reducing valve)

(4) G (PF) 3/8 with O-ring

(T)

(P)

(4), (5) (5) G (PF) 1/4 with O-ring

Reducing valve (for pilot)

Bucket cylinder 85V2E43001

(2) Note North America equipped M/c's have a quick connector in port (1) (3) for testing. K65V2E43001

Multiple control valve Note North America equipped M/c's have a quick connector in port (3) for testing.

(3) Main relief valve

Overload relief valve

65ZV43001

65ZV-2 US 43-4 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring loading circuit main relief pressure

Measuring loading circuit overload relief pressure

1. Unload the bucket.

1. Attach the pressure gauge to the port ((1) for the rod side, (2) for the bottom side, (3) for the both sides).

2. Lower the boom to the lowest limit. 3. Attach the pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) to the bucket cylinder bottom side (2).

2. Adjust the main relief valve pressure to 24.5 MPa (250 kgf/cm2) (3,555 psi) + 1/4 additional turn, so the pressure is above the overload relief pressure.

4. Set the parking brake switch to the "ON" position. 5. Move the bucket control lever to the roll back position. Hold the lever at that position.

Bucket cylinder bottom side (gauge port (2) or gauge port (3) ) 1. Lower the boom to the lowest limit.

6. Increase the engine speed to the maximum, and measure and record the pressure using the pressure gauge.

2. Move the bucket control lever to the roll back position.

Adjusting main relief pressure

3. Keep the engine speed at low idle. 4. Hold the bucket control lever at the roll back position and record the pressure.

Adjusting screw

Bucket cylinder rod side (gauge port (1) or (3) ) 1. Keep the boom horizontal. 2. Move the bucket control lever to the dump position, hold and then measure and record the pressure. Adjusting overload relief pressure

Lock nut Main relief valve

70ZV43004

Lock nut

Adjusting screw

IMPORTANT At the completion of check and adjustment of main relief valve pressure, be sure to tighten the lock nut.

Overload relief valve

70ZV43005

65ZV-2 US 43-5 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring pilot circuit relief pressure

IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.

WARNING Trapped pressure in brake circuit could cause serious injury when the plug is removed. Fully release all residual accumulator pressure before servicing. 1. Attach the pressure gauge to the port ((4) or (5)). 2. Keep the engine speed at low idle (when the brake line pressure is normal) and then measure and record the pressure.

Adjusting pilot line pressure

Lock nut

Adjusting screw

Reducing valve

80ZVE43005

Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the pilot line pressure.

IMPORTANT After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut.

65ZV-2 US 43-6 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Ride control circuit reducing valve setting pressures (OPT) WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service man. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine

Measurement instruments Pressure gauge 15 MPa (150 kgf/cm2) (3,000 psi) (for ride control line) with 3 m (10 ft.) hose Note For safety, route the gauge to an area where it may be safely read by the person doing the test.

Standard measurement value Ride control line pressure (reducing valve) MPa (kgf/cm2) (psi)

7.4±0.3 (75±3) (1,067)

Hydraulic oil temperature: 50±5ºC (120±9ºF)

Gauge port

Gauge port location Reducing pressure

SP2

G (PF) 3/4 with O-ring

From pump

(11)

Releasing residual pressure from tank and pipes

(12) KAYABA INDUSTRY CO,LTD TOKYO JAPAN

Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground.

(18) B

B T

SP2

Tilt down the bucket until it comes in contact with the ground. Place the bucket control lever in the roll back position, and then lower the boom.

Push down on, then open the cap of the hydraulic tank to release the residual pressure.

Port size

(15)(16) Boom cylinder bottom side

Boom cylinder rod side K65V2E43002

65ZV-2 US 43-7 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring ride control circuit reducing pressure

Adjusting reducing valve pressure

1 21 23 (18) 22

Depressure valve section

Reducing valve section

70V2U43001

85V2E43003

1. Loosen lock nut (23) and depressure valve (18) for releasing internal pressure from accumulator circuit. : Valve (18): 7 N-m (0.7 kgf-m) (5 lb-ft) : Nut (23): 13.6 N-m (1.4 kgf-m) (10 lb-ft) 2. Attach the pressure gauge to the gauge port SP2. : Plug SP2: 165 N-m (16.8 kgf-m) (121 lb-ft) 3. Keep the engine speed at low idle and then measure and record the pressure.

Loosen lock nut (21) and adjust the pressure by adjusting screw (22). : Lock nut (21): 29 N-m (3.0 kgf-m) (22 lb-ft) Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

IMPORTANT At the completion of check and adjustment of reducing valve pressure, be sure to tighten the lock nut.

65ZV-2 US 43-8 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Steering circuit relief valve setting pressures WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service man. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine

Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for steering line with 1.5~3 m (4~10 ft.) hose) Note For safety purpose, route the gauge to an area where it may be safely read by the person doing the test.

Standard measurement value Steering line main relief pressure (at maximum speed) MPa (kgf/cm2) (psi)

20.6±0.5 (210±5) (2,986±71)

Steering line overload relief pressure (at idling speed) MPa (kgf/cm2) (psi)

23.5±0.7 (240±10) (3,407±101)

Hydraulic oil temperature: 50±5ºC (120±9ºF)

Gauge port Gauge port location Main relief pressure (1), (2)

Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground. Tilt down the bucket until it comes in contact with the ground. Place the bucket control lever in the roll back position, and then lower the boom. Push down on, then open the cap of the hydraulic tank to release the residual pressure.

Port size

Overload relief pressure

G (PF) 1/4 with O-ring

65ZV-2 US 43-9 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring steering circuit main relief pressure

Steering cylinder

(1)

Note (2) North America equipped M/c's have quick connectors at ports (1) and (2).

Adjusting steering line main pressure The pressure is adjusted by the main relief valve on the priority valve. Remove the hose nipple of the relief valve and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the steering line main pressure.

Priority valve A

K65V2E43003

1. Attach the pressure gauge to the gauge port ((1) or (2)). 2. In case the pressure gauge is installed to (1), steer the machine to the left until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned. When measuring oil pressure, be sure to apply the articulation stopper until the front and rear chassis contact each other.

WARNING If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death. After the measurement, be sure to disconnect and store the articulation stopper. 3. Increase the engine speed to high idle, and measure and record the pressure.

Relief valve Adjusting screw

70V2E43001

Note - Allen wrench size of 7/32" fits snugly. - Remove pressure from tank by depressing tank cap and relieving air. - Do this twice, and wait for about 60 seconds between each time that the cap is depressed to permit pressure to equalize. - A 1/4 turn clockwise of the adjusting screw raises the pressure about 2.1 Mpa (21 kgf/cm2) (300 psi).

65ZV-2 US 43-10 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring steering circuit overload relief pressure Orbitrol

Adjusting overload relief pressure The pressure is adjusted by the overload relief valve on the orbitrol®. Turn clockwise the adjusting screw to raise the steering line overload relief pressure. Note It is not possible to adjust the overload relief pressure if the orbitrol® is removed.

E E

IMPORTANT

Overload relief valve Adjusting screw

E-E 70V2E43002

1. Attach the pressure gauge to the port ((1) for the left turn, (2) for the right turn). 2. Adjust the main relief valve pressure to 25.5 MPa (260 kgf/cm2) (3,697 psi) + 1/4 additional turn, so the pressure is above the overload relief pressure. 3. Steer the machine until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned. 4. Keep the engine speed at low idle, and measure and record the pressure. Raise the engine speed to 1,000 min-1 if fail to do.

At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.

65ZV-2 US 43-11 43 Check & Adjustment Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Cylinder natural drift

Measurement procedure 1. Unload the bucket.

WARNING Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused. To prevent such an accident, be sure to lock the boom and bucket control levers in the cab, securely support the boom, and remove the starter key. In addition, hang a "DO NOT OPERATE!" tag on the steering wheel.

2. Keep the boom and bucket horizontal. 3. Set the parking brake switch to the "ON" position. 4. Lock the boom and bucket control levers using the safety lock. 5. Stop the engine. 6. Mark the cylinder rod at a point 100~150 mm (4~6 in) away from the cylinder head cover.

Measurement instrument

7. Measure the accurate distance from the cylinder head cover to the vinyl tape. This is distance "A" mm (in). Measure the distance again 5 minutes later. This is distance "B" mm (in).

- Scale 150~300 mm (1 ft.) - Stop watch

Cylinder drift (mm/min) A – B (mm) (in) = -------------(in/min) 5 (min)

- Black vinyl "electrician's" type Note Warm-up the hydraulic oil before measuring cylinder drift.

Standard measurement value Boom cylinder (mm/min) (in/min)

3 (1/8) or less

Bucket cylinder (mm/min) (in/min)

4 (5/32) or less

65ZV-2 US 43-12 43 Check & Adjustment Hydraulic Group Hydraulic Cylinder Reference

Mark (Vinyl tape) Scale

70ZV43012

Drift rate depends on the viscosity of the hydraulic oil and its temperature. In other words, high temperature of the hydraulic oil reduces the viscosity. Reduction in oil viscosity increases oil leakage through the seals, and increases the drift rate. Cold thick oil reduces the drift rate.

IMPORTANT At the completion of measurement, if the vinyl tape used for measurement is not removed from the cylinder rod, the tape may be caught by the rod seal. The tape will cause oil leakage from the rod seal. To prevent oil leakage, be sure to remove the mark.

65ZV-2 US 52-1 52 Function & Structure Brake Group

52 Function & Structure Brake Group Brake System Outline.............................................. 52-2 Brake Units Layout .................................................. 52-3 Unloader Valve ........................................................ 52-4 Valve Unit ................................................................ 52-6 Accumulator ............................................................ 52-8 In-Line Filter ............................................................ 52-9 Brake Valve ............................................................. 52-10 Service Brake .......................................................... 52-14 Parking Brake.......................................................... 52-17 Parking Brake Manual Release............................... 52-20 Parking Brake Spring Chamber............................... 52-22 Brake Circuit Check Valve....................................... 52-23 Pressure Sensor (for stop lamp and declutch) ........ 52-24

65ZV-2 US 52-2 52 Function & Structure Brake Group Brake System Outline

Brake System Outline The brake system is the all-hydraulic type, and has two independent systems consisting of the front system and the rear system for enhancing safety. The service brake is the wet disc type. The parking brake is the internal expansion drum type.

Service brake Oil from the pump is regulated in a range from 6.9~11.8 MPa (70~120 kgf/cm2) (995~1,706 psi) by the unloader valve (22), and accumulated in accumulator (33) provided for the front and rear wheels. When brake valve (23) is depressed, the pressure oil in the accumulator enters the disc brake piston chamber for the front and rear wheels, pushes the piston, and generates braking power.

Parking brake The internal expansion type drum brake for parking is applied by spring chamber (55). Spring chamber (55) operates when the pressure oil inside the spring chamber returns to the tank while the power is not supplied to solenoid valve (35) (that is, while the parking switch is ON).

Adjustment of axle internal pressure While the brake pedal is not pressed, the internal pressure of the hydraulic tank is always applied on the brake piston chamber, and there is a possibility that the brake may drag. To prevent the brake from dragging, the axle housing air chamber is connected to the hydraulic tank air chamber so that the pressure inside the axle housing becomes equivalent to the pressure inside the hydraulic tank.

65ZV-2 US 52-3 52 Function & Structure Brake Group Brake Units Layout

Brake Units Layout The brake system is the all-hydraulic type, and has two independent systems consisting of the front system and the rear system for enhancing safety.

The service brake is the wet disc type. The parking brake is the internal expansion drum type.

K65V2E52001

1. Accumulator (for brake) 2. Solenoid valve (for parking) 3. Brake valve 4. Parking brake 5. Spring chamber (for parking brake) 6. Unloader valve 7. Brake/Pilot manifold

65ZV-2 US 52-4 52 Function & Structure Brake Group Unloader Valve

Unloader Valve

To accumulator

B-B

To tank

To fan motor

21 22

25 19

26 18

10 1

3 16 Filter

4 15

Pilot port (accumulator feedback port)

A-A

From pump

Fan motor port

Accumulator port

Pump port

Fan motor port Pilot port (accumulator feedback port)

Tank port

Rc 1/8

Tank port

Accumulator port

P Pilot port (accumulator feedback port)

Hydraulic circuit diagram

1. Body 2. Spring 3. Spool 4. O-ring 5. Plug 6. Orifice 7. Orifice 8. O-ring 9. Plug 10. Plug (gauge port) 11. Governor plunger 12. Spring 13. O-ring

Pump port K115ZV52002

14. Plug 15. Pilot valve 16. Spring seat 17. Spring 18. Spring 19. O-ring 20. Plug 21. Adjusting screw 22. Lock nut 23. — 24. — 25. Seat 26. O-ring

65ZV-2 US 52-5 52 Function & Structure Brake Group Unloader Valve The unloader valve controls the flow rate and the pressure of the hydraulic oil sent from the pump to the accumulator. Body (1) is equipped with ports (pump, fan motor, accumulator, pilot and tank). Spool (3) which opens and closes the pump port to the fan motor port, orifice (6) which regulates the flow rate to the accumulator port with high priority, and the pressure governor mechanism which controls the pressure on the accumulator port side are built in the unloader valve.

Unloader valve operation While the unloader valve is not operating, spool (3) is pushed back by spring (2) and the pump port to the fan motor port is closed. Oil flowing from the pump port is sent to the accumulator port through orifice (6), and the pressure at the accumulator port increases accordingly. When an excess flow rate is generated, spool (3) moves to the fan motor port side and the excess flow rate flows out to the port to the fan motor. The pressure at the accumulator port is transferred to the inside of the pressure governor through orifice (7). When the pressure at the accumulator port increases and exceeds the load of springs (17)(18) applied on pilot valve (15), the pilot valve opens and increase of the pressure at the accumulator port stops (cut-out pressure). At this time, the pressure in the accumulator connected to the pilot port pushes governor plunger (11), and continuously releases the pilot valve. When the pressure in the accumulator decreases and the spring attached to the pilot valve pushes back the governor plunger, the pilot valve is closed and the pressure at the accumulator port starts to increase again (cut-in pressure). Setting pressure

OFF

11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi)

6.9±1.0 MPa (70±10 kgf/cm2) (995±142 psi)

65ZV-2 US 52-6 52 Function & Structure Brake Group Valve Unit

Valve Unit 4

Note Unloader valve (PI) "Feed back" signal is acquired from front brake accumulator.

Loading line pilot valve

(PPI)

(Z)

(Z1)

(Z2) (PA)

ACF

(ACCF)

Spring chamber for parking brake

(ACCR) (PI)

(PARKING)

(TA)

Unloader valve "feed back" signal

(P) Tank

Pump port (from unloader valve)

(T)

High pressure test ports

P=Pump supply T=Tank circuit PI=Pump feedback to unloader (From ACCF circuit) ACCR=Accumulator circuit-rear ACCF=Accumulator circuit-front PPI=Pilot valve 85V2E52002

WARNING

ACCR

ACCF To parking brake ACF Rc1/8

1 B

2 P

B A

PA G3/8

Z2 G1/4

ACF T Rc1/8 G1/2

Z PPI TA Z1 G1/4 G3/8 G3/8 G1/4

85V2E52003

1. Solenoid valve for parking brake 2. Reducing valve [3.5 MPa (36 kgf/cm2) (512 psi)] (Serves as pressure for loading pilot control and park brake) 3. Check valve 4. Accumulator low pressure sensor Set value by MCU [3.9±0.5 MPa (40±5 kgf/cm2) (569±71 psi)]

Injection Hazard High pressure test ports contain accumulator pressure [11.8 MPa (1,706 psi)] that can escape from these 2 plugs. Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these test plugs. 135ZV52035

65ZV-2 US 52-7 52 Function & Structure Brake Group Valve Unit

Accumulator low pressure sensor

View A 1: Power (+) 2: Output (+) 3: Common

(V) 5 4 3 2 1

10 (102) (1422)

20 (204) (2844)

30 35 MPa 2 (306) (351) (kgf/cm ) (4351) (4991) (psi)

95V2E52095

65ZV-2 US 52-8 52 Function & Structure Brake Group Accumulator

Accumulator Nitrogen gas chamber

7 10 3 2 4 5

Hydraulic oil chamber

6 9 8

65ZV52005

1. Shell 2. Bladder 3. Poppet 4. Film 5. Holder 6. Oil port 7. Gas plug 8. O-ring 9. Back-up ring 10. Label

The accumulator holds a reserve of pressurized oil for the brake circuit prevent disability of the brakes caused by a problem with the pump, etc. Two accumulators are provided in the service brake line. Nitrogen gas at 2.94 MPa (30 kgf/cm2) (427 psi) is charged in the gas chamber.

WARNING Never weld on or near gas charged accumulator. Serious injury may result. When disposing, wear protective glasses and loosen plug to release gas in the accumulator completely. Do not remove plug.

Accumulator specifications Maximum operating pressure MPa (kgf/cm2) (psi)

11.8±0.5 (120±5) (1,706±71)

Nitrogen gas charging pressure MPa (kgf/cm2) (psi)

2.94±0.1 (30±1) (427±14)

Nitrogen gas capacity L (gal)

0.5 (0.132)

65ZV-2 US 52-9 52 Function & Structure Brake Group In-Line Filter

In-Line Filter

From unloader valve

To combination valve

FILTER

5 70ZV42040

1. Case 2. Nipple 3. Strainer

4. O-ring 5. O-ring

Accumulator

Unloader valve

In-line filter Valve unit

K65V2E52002

This 95 micron filter protects the brake manifold and related valves from contamination.

become lodged & may not blow out with compressed air, but may release later & cause erratic valve troubles.

It must be back flushed to keep it clean. Replace it when there has been any system contamination or if the pilot and brake pump has failed. Pieces of debris can

It is called out as item No. 81 in the brake diagram.

65ZV-2 US 52-10 52 Function & Structure Brake Group Brake Valve

Brake Valve 34

A 28

44 45 A-A

51 16 50

A 17

18 29

22 19

23 Rear brake port

Accumulator port

6 Front brake port

11 Accumulator port

Tank port

2 5 3

4 8

1. Body 2. Spool 3. Spring seat 4. Snap ring 5. Plunger 6. Spring 7. Plug 8. O-ring 9. C-ring 10. Orifice 11. O-ring

Pressure sensor port

B 9

12. Body 13. Cover 14. Oil seal 15. Plate 16. C-ring 17. Spool input 18. Spring seat 19. Retainer 20. Bolt 21. Spring 22. Spring

B-B

23. Case 24. Spring 25. Seat 26. Dust cover 27. Mounting plate 28. Pedal bush 29. Bolt 30. Spring washer 31. Pedal 32. Roller

33. Spacer 34. Pedal pin 35. L-pin 36. Washer 37. Pin 38. Shaft 39. Spacer 40. Joint 41. Pin 42. Boot

70V2E52002

43. Snap ring 44. Shaft 45. Bolt 46. Washer 47. Nut 48. Plate 49. Spring 50. Screw 51. Nut 52. Pedal cover

65ZV-2 US 52-11 52 Function & Structure Brake Group Brake Valve

Brake valve performance chart

Pedal pressing force (F)

N (kgf) (lbf)

331 (33.8) (74.4)

300 (30.6) (67)

200 (20.4) (45)

125 (12.7) (27.9)

100 (10.2) (22) 72.3 (7.4) (16.3)

55.5 (5.7) (12.5) 0

3.9

9 10

Pedal stroke

18.5 19

(deg)

Output oil pressure (Brake port)

MPa (kgf/cm2) (psi) 4 (40) (580)

2 (20) (290)

0.64 (6.5) (92.4) 0

3.9 5

9 10

Pedal stroke

18.5 19

(deg) K65V2E52003

65ZV-2 US 52-12 52 Function & Structure Brake Group Brake Valve

Brake valve outline

While the valve is not operating

The brake valve is integrated into the pedal converts the pump oil pressure into the pressure corresponding to the pedal pressing force, and transmits it to the brake.

The brake valve is the tandem type, and consists of two independent systems. When the right side pedal is depressed, the movement of right side pedal is transmitted to a left side pedal by the linkage and brake is applied. But when the left side pedal is depressed, only left pedal is worked. 32

The valve is the closed center type (in which the import is closed while the pedal is released). High pressure is always applied on the in-port side to improve the responsiveness during operation.

17 22 24

21 B1 Rear brake

Accumulator

2 5 6 B2 Front brake 2 5 B

Tank T

Pressure sensor port

B-B 70V2E52004

65ZV-2 US 52-13 52 Function & Structure Brake Group Brake Valve Between spool input (17) and spools (2) in the brake valve, springs (21)(24) which convert pedal pressing force into output oil pressure are installed. In addition, two spools (2) are installed for series in the center of the main body of the brake valve. Plungers (5) which transmit the control oil pressure to spool as the hydraulic reactive force are built in each spool. While the valve is not operating, each spool is returned to the non-operation position by spring (6). As a result, the passages from out-ports B1, B2, and pressure sensor port to tank port are opened, and the pressure inside the brake piston chamber becomes equivalent to the pressure in the tank. In addition, oil sent from the pump is stored in the accumulator, and sent to the in-ports A1 and A2. But the passages from in-ports A1, A2 to out-ports B1, B2 and pressure sensor port are shut down by each spool (2), and high pressure oil from the accumulator is maintained.

While the valve is operating When the brake pedal is pressed, spool input (17) is pushed by way of roller (32). Spool input (17) lets each spool (2) drop down by way of springs (21)(24). When spools (2) are pushed down, at first the passage from out-port B1, B2, and pressure sensor port to the tank port are shut down. When spools (2) are pushed down further, the passages from in-ports A1, A2 to out-ports B1, B2 are opened and pressure oil from the accumulator is sent to the brake piston chamber to apply the brake. Pressure oil of in-ports A1, A2 side act on plunger (5) inside each spool (2) through the orifices and works as the hydraulic reactive force to return spool (2) upward. When the sum of hydraulic reactive force and spring load (6) becomes balanced with the spring load (21)(24), it returns spools (2) to shut down the passages A1-B1 and A2-B2 to hold the pressure. By this operation, the load of springs (21)(22)(24) by deflection are transmitted to the operator as pedal pressing force and the pressure in proportion to the pedal pressing force is obtained.

While the valve is releasing When the brake pedal is released, spool input (17) is pushed back by spring (22). The compressed springs (21)(24) is extended, and each spool (2) is returned upward to the non-operation position by the sum of hydraulic reactive force and spring load (6). After the passages from out-ports B1,B2 and pressure sensor port to in-ports A1, A2 is shut down by spool (2), the pressure of out-ports B1,B2 and pressure sensor port is opened to tank port, and then the brake operation is released.

65ZV-2 US 52-14 52 Function & Structure Brake Group Service Brake

Service Brake 10

Differential gear assembly

Service brake operation When stepping on the brake pedal, the brake oil from the differential gear housing oil inlet enters the brake piston chamber and presses brake piston (3) to the left. Then the brake piston presses steel plate (4) against friction plate (5). Since friction plate (5) rotating with sun gear (6) is placed between brake backing plate (7) and steel plate (4), it makes the rotation speed of the sun gear decrease or makes it stop.

12 11

65ZV52006

1. Axle housing 2. Internal gear 3. Brake piston 4. Steel plate 5. Friction plate 6. Sun gear 7. Brake backing plate 8. O-ring (for brake piston inner) 9. O-ring (for brake piston outer) 10. Spider 11. Planetary gear 12. Pin The service brake is an enclosed wet-type single-plate hydraulic brake, and is incorporated in the axle housing. This type of service brake ensures good braking power and protects the brakes from mud or sand.

65ZV-2 US 52-15 52 Function & Structure Brake Group Service Brake

Service brake friction plate 9

0.15 mm (0.354

0.006 in)

0.15 mm (0.276

0.006 in) 1

298 (11.732 in)

0.65 mm (0.026 in) or more 1 +0.3 mm 0 (0.039+0.012 in) 2

5.7 0.3 mm (0.224 0.012 in) Detailed drawing of groove 65V2E52001

1. Plate 2. Lining The friction plate has linings (paper material) on the contact faces on both sides.

Service brake steel plate

304 (11.968 in)

210 (8.268 in)

170 (6.693 in)

8 - 00.2 mm 0 (0.315 - 0.008 in)

65V2E52002

65ZV-2 US 52-16 52 Function & Structure Brake Group Service Brake

Brake circuit air bleeding procedure

Bleeding air from brake pipes

WARNING Unexpected movement of the machine may cause a severe accident. To prevent such an accident, take the following safety measures when performing air bleeding with the engine running. - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the wheel from moving. - Determine the signals between the persons related to this work for engine starting to prevent an accident. - When moving up the boom, install a safety column under the boom. - Apply the articulate stopper.

IMPORTANT Before bleeding the service brakes, it is important to remove all air from the brake valve manifold block, and all related valves. These include the reducing valve and park brake valve. Failure to do this correctly will result in unsatisfactory brake modulation.

Vinyl tube

Air bleeder nipple

Oil can 65ZV52009

1. Connect a vinyl tube to the air bleeder nipple provided in the differential gear housing, and place an oil can for hydraulic oil recovery. (The air bleeder nipple is equivalent to the one provided in the left brake valve). Vinyl tube length 1.2~1.3 m (4 ft) Air bleeder nipple outside diameter

Approx. 8 mm (0.315 in)

Perform the following to do this: 1. Verify that the wheels are securely blocked, and the articulation lock is in the "locked" position. 2. Charge accumulator to full pressure, then shut off engine, and complete procedure. 3. Turn the park brake solenoid valve release knob counterclockwise then back to neutral five times with a five second wait period between each turn. Position this back to the normal position when finished.

60ZV52011

2. Loosen the air bleeder nipple a little. Press and hold the left brake pedal until oil containing no air comes from the air bleeder nipple. After that, tighten the air bleeder nipple. Perform this operation for each of the four wheels. : Air bleeder nipple 25 N-m (2.6 kgf-m) (19 lb-ft)

65ZV-2 US 52-17 52 Function & Structure Brake Group Parking Brake

Parking Brake 5

B-B 5 A

Drum rotational direction for traveling in reverse

C 4 1 C D

D A

2 Adjusting screw rotational direction for brake shoe expansion

A-A

D-D

C-C 80ZVE52005

1. Support plate 2. Brake shoe 3. Brake lining 4. Adjusting screw 5. Cam shaft 6. Lever The parking brake is a propeller shaft braking drum type, and is connected to the transmission output shaft.

65ZV-2 US 52-18 52 Function & Structure Brake Group Parking Brake

Parking brake operation

Parking switch

Operation chart parking brake

+ Oil

Spring chamber Solenoid valve

Bracket Lever

Link Pin Link Pin Parking brake

70ZV52018

Turning on (pulling out) the parking switch turns off the power of the solenoid valve (shown in the figure). Oil is discharged from the spring chamber to the tank, and the spring in the spring chamber pulls parking brake lever (6). Since lever (6) is connected to cam shaft (5), the cam shaft rotates when the lever is pulled up. The rotation of the cam shaft causes the shoes on both sides of the cam to expand. As a result, the rotating brake drum is stopped.

Parking switch

OFF

Solenoid valve

Power-off

Power-on

Spring chamber

Oil discharge

Oil feeding

Parking brake

Braking

Released

65ZV-2 US 52-19 52 Function & Structure Brake Group Parking Brake

Parking brake solenoid valve Spring chamber (brake actuator) B

Reducing valve

Solenoid

Knob

T Seat face A

Seat face B

Manual release (counterclockwise rotation)

Spool

Tank

P T Hydraulic circuit diagram

Solenoid valve operation

Solenoid valve specifications

Amp

a 0

Volt

Varistor 95ZV42079

While the parking switch is ON (that is, while the power is not supplied to the solenoid), the seat face A is closed and the seat face B is open. As a result, the spring chamber port is connected to the tank, and the parking brake is applied. When the parking switch is set to OFF (that is, when the power is supplied to the solenoid), the spool is pushed to the left, the seat face A is open, and the seat face B is closed. As a result, the oil from the reducing valve enters the spring chamber, and the parking brake is released. Note The varistor (variable resistor) is used for the solenoid coil to protect the circuit.

Voltage

DC 24 V

Current

0.92 A

Resistance

26.2 

85V2E52007

65ZV-2 US 52-20 52 Function & Structure Brake Group Parking Brake Manual Release

Parking Brake Manual Release

Valve assembly

Solenoid valve for parking brake

Rear chassis Installation position K65V2E52004

WARNING Sudden accidental movement of the machine could result in serious injury or death. Before manually operating the parking brake solenoid: - Lower the boom and attachment to the ground. - Place chocks on both sides of the tires. - Be sure the machine is in neutral and engine is stopped. Note If the park brake cannot be released due to an electrical problem, such as a failed park brake solenoid valve coil or electrical circuit, perform the following operation.

65ZV-2 US 52-21 52 Function & Structure Brake Group Parking Brake Manual Release Method 2

Method 1

Parking brake spring chamber (actuator)

Lever Valve assembly

Link Pin ON

Link

OFF Rope or wire Prybar (used as nail puller-carpentry)

70ZVE52006

Solenoid valve for parking brake

To release the parking brake while the regular oil pressure source may not function due to an engine related trouble, etc., perform the following operation.

Knob

Turn it counterclockwise.

85V2E52009

Turn the park brake solenoid valve knob counterclockwise. When you feel the detent position of the solenoid valve, this will turn the park brake valve "OFF", and supplies oil to the spring chamber, thereby releasing the park brake.

WARNING If the manual operation knob is not returned to the running position, the parking brake is disabled and may result in a severe accident. Be sure to return the manual operation knob to the OFF position after releasing the parking brake by hand. Test the operation of park brake by using the controls in the operators cab.

- When there is another oil pressure source Supply oil pressure to the oil inlet of park brake spring chamber from another oil pressure source, then remove the pin when it releases. - When there is no other oil pressure source Secure a rope or wire to the link, pull downward on the rope or wire with a prybar to control the spring force of the spring chamber, then remove the pin when it releases.

65ZV-2 US 52-22 52 Function & Structure Brake Group Parking Brake Spring Chamber

Parking Brake Spring Chamber 2

7 4 5

6 3

Oil

65ZV52018

1. Cylinder tube 2. Piston rod 3. Piston 4. Rod cover 5. Cap 6. Spring 7. Bushing 8. U-packing 9. O-ring 10. Wear ring 11. Dust seal 12. Filter 13. Set screw 14. Set screw

1,736 N (177 kgf) (390.2 lbf)

1,079 N (110 kgf) (242.5 lbf)

160 (6.299)

60 stroke (2.362)

(Installation length) 220 (8.661)

99 (3.898)

(Free length) 319 (12.559) Spring specification [mm(in)]

70ZVE52003

The oil applies pressure to the internal spring to release the parking brake.

WARNING Careless disassembling work may cause serious injury or death. The spring applies high force to the rod cover, therefore carefully disassemble the spring chamber using a press.

65ZV-2 US 52-23 52 Function & Structure Brake Group Brake Circuit Check Valve

Brake Circuit Check Valve

Poppet (T)

(P) (TA)

Pump supply through reducing valve

Seat face

(PARKING)

(ACCR)

(ACCF) (PA) (Z1)

(Z2)

(ACF)

(Z)

(PPI)

B (ACCF) Reducing valve

Accumulator Valve assembly

Hydraulic circuit diagram

The pressure oil fed from the pump pushes down the poppet, opens the seat face, and flows into the accumulator circuit. It also flows into the reducing valve. (ACCF side only) When the pressure oil is not fed from the pump (either the unloader valve is "cut-out" or the engine is shut off), the poppet is pushed up by the pressure in the accumulator circuit, and the seat face is closed to prevent back flow. This allows the accumulator circuit to store oil under pressure for emergency braking. There is one check valve for the front brake accumulator circuit and another for the rear.

P=Pump supply T=Tank circuit PI=Pump feedback to unloader (from ACCF circuit) ACCR=Accumulator circuit-rear ACCF=Accumulator circuit-front PPI=Pilot valve circuit 85V2E52010

65ZV-2 US 52-24 52 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure Sensor (for stop lamp and declutch) Pressure sensor (for Declutch) Refer to "Electrical Group: "Adjustable declutch preset switch" page 62-35".

Pressure sensor (for stop lamp) This pressure sensor whose set valve is controlled by the MCU is installed between the brake valve and the front brake. When the brake pedal is depressed and the pressure increases to the set valve of the MCU (0.26 MPa (2.6 kgf/cm2) (37.0 psi)), the stop lamp turns on.

Left brake valve

Pressure sensor for stop lamp and declutch

80V2E52007

65ZV-2 US 52-25 52 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure sensor (stop lamp)(S/N 5001~5200)

View A 1: Power (+) 2: Output (+) 3: Common

85V2E52012

(V) 5

Output voltage

4 3 2 1

1 (10) (140)

2 (20) (285)

3 (30) (435)

4 (40) (570)

5 (50) (715)

MPa (kgf/cm2) (psi)

Pressure 65V2E52003

65ZV-2 US 52-26 52 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure sensor (stop lamp)(S/N 5201~)

GND

Vout

Vdd

View A K80V2U52003

(V) 5

Output voltage

1.08* (11)(157)

4.31* (44)(625) Pressure

5.4 (55)(783)

MPa (kgf/cm2)(psi) *: Calibration point

K80V2U52004

65ZV-2 US 53-1 53 Check & Adjustment Brake Group

53 Check & Adjustment Brake Group Brake Circuit Oil Pressure ....................................... 53-2 Service Brake .......................................................... 53-6 Parking Brake.......................................................... 53-8

65ZV-2 US 53-2 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake Circuit Oil Pressure Unloader valve setting pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men.

(PPI)

(Z2)

(Z)

(Z1)

(PA)

ACF

(ACCF)

(ACCR)

(PARKING) (TA)

(T)

(P)

ACF port

Valve assembly

85V2E53001

WARNING

Injection Hazard Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these test plugs. 135ZV52035

Brake line main pressure is regulated by the unloader valve.

65ZV-2 US 53-3 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Unloader valve setting pressure measurement Measurement instrument

Unloader valve setting pressure adjustment

22 Fan motor port

Hydraulic pressure gauge 20 MPa (200 kgf/cm2) (3,000 psi)

Gauge port ACF port on valve assembly Rc (PT) 1/8

Standard measurement value Pump port Cut-out

11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi)

Cut-in

6.9±1.0 MPa (70±10 kgf/cm2) (995±142 psi)

Measurement procedure 1. Lower the boom to the lowest limit, and tilt the bucket down to the ground. Then set the parking brake switch to the "ON" position. 2. Stop the engine. Repeatedly depress and release the brake pedal till you feel light brake to discharge accumulator pressure. 3. Remove one of the ACF port plug on the valve assembly and attach the pressure gauge to the port. : ACF port: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft) 4. Start the engine, and keep the speed at low idle. Measure and record the pressure when the pointer of the pressure gauge stops rising (cut-out pressure). 5. Keep the engine at low idle, and repeatedly depress and release the brake pedal to reduce the accumulator pressure. Measure and record the pressure when the pointer of the pressure gauge stops, and then, starts rising again (cut-in pressure).

Unloader valve

K115ZV53002

1. Loosen lock nut (22). : Nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft) 2. Adjust the pressure by adjusting screw (21). urn the screw clockwise to raise the pressure. Note In a case that the "ON" or "OFF" pressure does not match the standard setting pressure, set the "ON" (cutin) pressure to the standard setting pressure.

65ZV-2 US 53-4 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve oil pressure

Brake valve oil pressure measurement Measurement instrument

Force

Gauge port 15 0 m m

Remove air bleeder nipple on the axle housing, and then install the pressure gauge to the bleeder position.

la ng

Hydraulic pressure gauge 10 MPa (105 kgf/cm2) (1,500 psi)

Size of air bleeder port: 7/16 - 20UNF

Air bleeder nipple [25 N-m (2.5 kgf-m)] 85V2E53002

65ZVE53001

Measurement procedure 1. Check to be sure the brake valve is fully released. 2. Press down the brake pedal to check that the oil pressure rises in proportion to the pedal angle. 3. Release the brake pedal to check that the oil pressure drops to zero in proportion to the pedal angle. In addition, visually check for brake oil leakage. Note If the pressure gauge is not available, refer to the pressure values displayed on the MODM. Refer to "Brake Pedal Output Oil Pressure" of MODM "Input/Output Monitor" page 62-73 and 92-64 for information.

65ZV-2 US 53-5 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve performance

Output oil pressure (brake port)

MPa (kgf/cm2) (psi) 4 (40) (580)

2 (20) (290)

0.64 (6.5) (92.4) 0

9 10

3.9 5

18.5 19

(deg)

Pedal stroke

K65V2E53001

Refer to the curve shown in the above figure. When the measured value does not match the performance curve, check the following points. Possible cause Malfunctioning brake valve

Solution Repair or replacement

Brake line oil pressure low (Pump, reducing valve malfunction)

Check and repair

IMPORTANT After measuring oil pressure, be sure to tighten the air bleeder valve. Also be sure to bleed air.

65ZV-2 US 53-6 53 Check & Adjustment Brake Group Service Brake

Service Brake Service brake performance check

Method 2

Method 1

If no test course as described "Method 1" is available, carry out the following method.

IMPORTANT

WARNING Separate the test course by using rope etc. and keep persons away from the test course. In addition, post persons in several positions near the course to warn others and avoid an accident while checking the service brake performance. Condition

The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine. Confirm engine & transmission performance via using a stall test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.

1. Test course Level, straight, dry and the paved ground. 2. Run the machine and depress the brake pedal at 35 km/h (22 mph). Measure and record the braking distance. Standard measurement value Braking distance 14 m (15 1/2 yard) or shorter Possible causes of extremely long braking distance Possible cause Low brake line pressure

Solution

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting brake performance check, be sure to observe the following items: - Place the machine on level ground. - Check that there is enough clearance for brake performance check around the machine. - During performance check, prohibit any person to walking near the machine. 1. Lower the boom to the lowest limit, and roll back the bucket fully until the bucket contacts to the stopper.

Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

Note The brake performance check condition and standard measurement value are based on the law and the regulation in Japan. When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.

2. Set the parking brake switch to the "OFF" position. 3. Set the declutch switch to OFF, and then depress the brake pedal all the way to the floor. 4. Set the shift lever to 2nd reverse speed. 5. Gradually increase the engine speed. The machine should not move at the maximum engine speed. Possible cause of machine moving during brake performance check Possible cause Low brake line pressure

Solution Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

65ZV-2 US 53-7 53 Check & Adjustment Brake Group Service Brake

Service brake friction plate wear measurement

Measurement procedure Remove drain plug (5) and drain gear oil. : Gear oil: 25 L (6.6 gal)/axle

WARNING Unexpected movement of machine may cause serious injury or death. To prevent such an accident, observe the following items before checking the brake valve: - Park the machine on level ground. - Apply the parking brake. - Stop the engine. - Determine the signals between the persons related to this work for engine starting to prevent an accident. - Prohibit any person from walking into the dangerous area.

While applying the service brake, insert the gauge through the drain port. Check the clearance (A). If the gauge does not turn, the friction plate is worn beyond specification and the plate needs to be replaced with a new one. Check at all four points. Wear limit (A): 7.9 mm (0.3 in) *Normally this procedure is done during oil change every 2,000 hours. - Gauge

Part No. 33240 20040 1

3 65ZV53002

CAUTION 5

1. Friction plate 2. Brake piston 3. Brake retainer 4. Steel plate 5. Drain plug

65ZV53003

At the completion of checking wear of service brake friction plate, be sure to fill the oil to the specified oil level. Gear oil 25 L (6.6 gal)/axle

65ZV-2 US 53-8 53 Check & Adjustment Brake Group Parking Brake

Parking Brake Parking brake performance check

Method 2

Method 1

If no test course available as described "Method 1", carry out the following method.

IMPORTANT

The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine. Confirm engine & transmission performance via stall test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.

Condition

Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting brake performance check, be sure to observe the following items: - Place the machine on level ground. - Check that there is enough clearance for brake performance check around the machine. - During performance check, prohibit any person to walking near the machine.

1. Test course 1/5 slope (Approx. 11º 19') 2. Bucket empty 3. Parking switch ON

WARNING

Standard measurement value 1. Set the parking brake switch to the "ON" position. No movement on 1/5 slope Possible cause of machine moving during brake performance check

2. Disconnect the cable connector of parking brake solenoid valve. 3. Set the parking brake switch to the "OFF" position.

Possible cause

Solution

Clearance between brake drum and shoe too large

Clearance adjustment

Improperly adjusted spring chamber link

Check and adjustment

Broken spring chamber spring

Check and repair

Parking brake solenoid valve malfunction

Check and repair

4. Place the shift lever to the 3rd reverse position. 5. Gradually increase the engine speed. The machine should not move at the maximum speed.

IMPORTANT If the machine begins to move with the parking brake applied, the brake shoes are burnt or misadjusted. At the completion of parking brake test, be sure to connect the connector of electrical line to the solenoid valve again.

65ZV-2 US 53-9 53 Check & Adjustment Brake Group Parking Brake

Possible cause

Solution

Clearance between brake drum and shoe too large

Clearance adjustment

Improperly adjusted spring chamber link

Check and adjustment

Broken spring chamber spring

Check and repair

Parking brake solenoid valve malfunction

Check and repair

Parking brake clearance adjustment Drum rotational direction for traveling in reverse

Brake lining Brake shoe

A D

D A

Adjusting screw rotational direction for brake shoe expansion

D-D

Adjusting screw

A-A 80ZV53002

WARNING Unexpected movement of the machine may cause serious injury or death. Adjusting parking brake clearance requires the parking brake to be released. So, to prevent accidental movement, observe the following items: - Park the machine on level ground. - Block the tires with chocks to prevent the wheels from moving. - Place the bucket to the ground. - Stop the engine, and then remove the starter key. Place "DO NOT OPERATE!" tag on the steering wheel. - Prohibit any person from walking into the dangerous area. If the machine moved during parking brake performance check, the clearance between the brake drum and the lining is too large.

65ZV-2 US 53-10 53 Check & Adjustment Brake Group Parking Brake

Adjustment procedure

Brake lining abrasion check

Shoe

Rivet

Abrasion limit

Inspection hole 2nd propeller shaft

Lining

Position of adjusting screw

Approx. 8º

Wear limit B : 0.8 mm (0.03 in) 80ZV53004

Rivet

12 rivets are inserted to fix the lining to the brake shoe. If the distance from the lining to the rivet head "B" is 0.8 mm (0.03 in) or less at one of the 12 rivet areas, replace the shoe assembly.

Brake shoe

A Brake lining

Lining thickness A: 6.15 mm (0.24 in) 80ZV53003

1. To rotate the brake drum during adjustment, lift the front and rear wheels on one side (or both sides) using safety jacks, cribbing, etc.. 2. Turn the inspection hole of the brake drum approximately 8º counterclockwise from the vertical position as shown in the figure. After that, use a screw driver or brake tool to turn the adjusting screw to adjust the clearance. Turn the adjusting screw clockwise (upward) to expand the brake shoes until the linings come in contact with the brake drum. After that, turn the adjusting screw 8 notches counterclockwise (down). The clearance will be adjusted to 0.23 mm (0.009 in). Adjustment range 0.10~0.25 mm (0.004~0.010 in) 3. After the adjustment, check the performance of the parking brake by referring to "Parking brake performance check".

65ZV-2 US 62-1 62 Function & Structure Electrical Group

62 Function & Structure Electrical Group How to Use Electrical Wiring Diagram .................... 62-2 Electrical Cable Color Codes .................................. 62-3 Electrical Circuit Symbols........................................ 62-4 Sensor Mount .......................................................... 62-5 Fuse ........................................................................ 62-6 Engine Start Circuit.................................................. 62-9 Power Generating/Charging Circuit......................... 62-16 ECM (Engine Controller) ......................................... 62-17 Transmission Control Circuit and Monitor Circuit .... 62-24 Instrument Panel and Switch................................... 62-44 MODM ..................................................................... 62-53 Electrical Detent Circuit ........................................... 62-92 Diode ....................................................................... 62-99

65ZV-2 US 62-2 62 Function & Structure Electrical Group How to Use Electrical Wiring Diagram

How to Use Electrical Wiring Diagram Example 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

WIDTH LAMP RELAY

RIDE CONTROL NEUTRAL RELAY RELAY

BACK LAMP RELAY

HORN RELAY

MCU FAULT RELAY

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW L A405 D001 1

LgW E218

(BLACK)

(BLUE)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 GL GO Br

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 PL RB RL GW

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR

(3)

The address method is used for electrical wiring diagrams. For this method, a symbol is attached to each connector and connector terminal in order to easily locate the other terminal where the other end of the cable is connected. Example 1 Symbol under (or above) connector, such as F6: Shows the address of the connector. Example 2 Symbol at the multi-terminal connector, such as 1 and 10: Shows the terminal number and the numbering direction.

95ZV62001

Example 3 Checking the other connector terminal where F704 RL (item (3)) is connected: 1. F704 Shows that the terminal is connected to the 4th terminal of the F7 connector. Check the description in the 4th terminal of the F7 connector (F704), it shows that the F704 terminal is connected to H128. This means that the 4th terminal of the F7 connector is connected to the 28th terminal of the H1 connector. 2. RL Shows the color of the wire "RL" represents that the insulation color is red, and "L" represents a blue stripe is on the red insulation.

65ZV-2 US 62-3 62 Function & Structure Electrical Group Electrical Cable Color Codes

Electrical Cable Color Codes Color of stripe Color of insulation

Y G (yellow) (green)

(sky blue)

Br (brown)

L (blue)

W (white)

R (red)

YSb

YBr

SbW

SbR

B O Lg (black) (orange) (light green)

Y (yellow)

G (green)

Sb (sky blue)

SbY

SbG

Br (brown)

BrY

BrG

BrL

BrW

BrR

BrB

L (blue)

LBr

W (white)

WBr

R (red)

RBr

B (black)

O (orange)

OSb

Lg (light green)

LgY

LgG

LgSb

P (pink) Gy (grey)

GyY

P (pink)

SbO

SbLg

SbP

LLg

RLg

BLg

LgL

LgW

LgR

LgB

GyG

GyL

GyW

GyR

LgBr

V (violet)

Insulation color Stripe color

70ZV62001

V (violet)

YGy

WV RGy

PB GyB

Gy (grey)

P GyO

Gy V

65ZV-2 US 62-4 62 Function & Structure Electrical Group Electrical Circuit Symbols

Electrical Circuit Symbols Name

Symbol

Name

Direct current

Motor

Alternating current

Equipment

Conductor (General)

Fuses

Branching connection

Lamp

Conductors (Connected)

Rectifiers

Conductors (Not connected)

Mechanical coupling

Terminal

Relay contact ("a" contact)

Ground

Relay contact ("b" contact)

Resistance or Resistor

Switch

Variable resistance or Variable resistor

Pressure switch or Temperature switch

Inductance or Electromagnetic coil

Negative -positive-negative (NPN) transistor

Battery or Direct voltage source

Positive -negative-positive (PNP) transistor

Symbol

65ZV-2 US 62-5 62 Function & Structure Electrical Group Sensor Mount

Sensor Mount 1 2 7

3 5

4 3 4

1. Machine speed sensor 2. T/C oil temperature sensor 3. Air cleaner sensor 4. E/G inlet air temperature sensor 5. Hydraulic oil level sensor 6. Hydraulic oil temperature sensor 7. E/G water temperature sensor (S/N 5001~5002)

65V2E62001a

65ZV-2 US 62-6 62 Function & Structure Electrical Group Fuse

Fuse The following fuses are provided to protect electrical circuits. Fusible link 70 A x 3, 30 A x 1 Fuse box 15 fuses x 2 (for chassis and cab) 1 fuse x 1 (for engine controller ECM) (For installation positions, refer to "Electrical Equipment Layout".)

CAUTION Possible burn hazard. Before replacing a fuse, be sure to turn off the starter switch.

IMPORTANT Replace a fuse with the same capacity. If a fuse blows immediately after replacement, the electric system is defective. Locate the defective part, and then repair it.

Fuse box For chassis

Fuse No.

Fuse capacity (A)

20A

LIGHTING HEAD LIGHT

15A

R. WORK LIGHT

SPARE

10A

BOOM KICKOUT BUCKET LEVELER

30A

15A

TURN SIGNAL

SPARE

30A

PARKING BRAKE MCU (MACHINE)

20A

15A

F. WORK LIGHT

SPARE

10A

AIR SUS. SEAT (OPT)

15A

SPARE

15A

SPARE

15A

4WAY FLASHER HORN ROOM LAMP RADIO

10A

FUEL PUMP

15A

SPARE

BUZZER MONITOR LAMP

10A

NEUTRAL RELAY SAFETY RELAY

15A

BATTERY RELAY ECM (ENGINE) GLOW PLUG RELAY

Protective circuit

15A SPARE 5A

For cab

Fuse No.

Fuse box for cab

Fuse box for chassis

90V2E62002

Fuse capacity (A)

Protective circuit

SPARE

R. WIPER / WASHER

10A

F. WIPER / WASHER

10A

MODM CIGAR LIGHTER

15A

SPARE

DC-DC CONVERTER

10A

SPARE

10A

SPARE

20A

SPARE

AIRCON

10A

AIRCON

20A

AIRCON

20A

SPARE

SPARE 20A SPARE 15A SPARE 10A SPARE 5A

65ZV-2 US 62-7 62 Function & Structure Electrical Group Fuse For engine controller (ECM) Fuse No.

Fuse capacity (A)

30A

Protective circuit ECM (ENGINE)

65ZV-2 US 62-8 62 Function & Structure Electrical Group Fuse

Fusible link

Problems caused by blown fusible link Fuse damaged

Fusible link Cover

Box for fusible link

(086) [W3]

30A

Fusible link

(900) [W5]

12V

R1 BR B AC R2 C

F13

(1)

(013) (Lg) 70A

F14

- The same conditions as "During engine operation".

IMPORTANT Starter

Battery relay

When replacing fusible link, you may want to disconnect the battery negative terminal to avoid arcing out a circuit and damaging wire.

[R5]x6 (910~ 915)

(701) [R5] (703) RL1.25

(702) [BW5]

B S

Safety relay

(706) WL1.25

(708) WP (707) WL

F13

Charge lamp (709) [R8]

70A (2)

(011) WB

F11

L B

R R1.25 (710) Alternator

70A

(723) [BR5]

(711) BrL

Fuel pump

10A

(724) [BR5]

F13 (725) [BR5]

(720) (BG)

Glow lamp

Glow plug

ECM(V10) (015) WR Glow plug relay

100

70A (2)

- The machine can be operated but the batteries can not be charged and the batteries will be discharged soon.

(700) WV

(063) WR1.25

(014) G1.25

- The same conditions as "During engine operation. - Engine can be started.

70A (1)

- Horn [and opt. flasher] will operate. - All the others will not operate and the machine can not be operated. - Engine will not stop automatically but can be stopped with starter switch OFF.

(708) WP

(015) WR

15A

10A

(064) G1.25

MCU

Battery

ECM (V24) (065) WR1.25 F15

30A

- All the electrical circuit will not function. - Engine can not be started.

70ZV62010

100

(060) (901) W [W5]

During engine stop

- Engine will stop automatically. - All the power for all electrical circuit will be OFF.

Fuse element

12V

Problem (symptom) During engine operation

To pilot lamp

ACC’

Fusible link location

E/G

Secondary steering pump

E 65V2E62012

The fusible link is located in the box as shown in the above figures. If excessive current flows through the starter switch or the electric line downstream of the starter switch due to short-circuit, the fuse element will be blown to protect the circuit. The condition of the fuse element can be seen through the transparent cover. Determine the cause before replacing the fusible link. For replacement of a fusible link, remove 2 bolts and pull it up.

65ZV-2 US 62-9 62 Function & Structure Electrical Group Engine Start Circuit

Engine Start Circuit Engine start circuit diagram Starter switch

B BR ACC R1 R2 C PREHEAT OFF ON START

MCU

F N R

30A

B12

Fusible link

12V

Battery

ECM

B11

Diode unit

F15 15A

23A D12 D05

Battery relay

D03 (1)

D10

Starter motor

70A

D04

12V

B18

F14

D11

E04 E12 E03 E11

10A

E24

Shift lever F/R position

E05 E06 E17

+24 V

B S E

Safety relay 3 2

B C R

Neutral relay

* When shift lever is in F/R position: OFF When shift lever is in N position: ON

+24 V (F5)

F13

MCU E24

Charge lamp 70A (2)

Alternator

65V2E62020

65ZV-2 US 62-10 62 Function & Structure Electrical Group Engine Start Circuit

Neutral starter To prevent the machine from unexpected movement at engine start up, the machine is so designed that the engine can start only while the shift lever is in the neutral (N) position.

Shift lever neutral (N) position When the starter switch is turned to the ON position while the shift lever is located in the N position, the coil actuation circuit of the neutral relay is connected to the ground of the MCU unit and the contact of the neutral relay is switched over to ON. When the starter switch is turned to the START position, the start command current flows from the starter switch terminal C to the safety relay via the neutral relay. As a result, the starting current flows in the starter motor, and the engine starts.

Shift lever forward/reverse (F/R) position While the shift lever is located in the F or R position, the power is not supplied to the neutral relay coil, and the main contact is OFF. As a result, the starting current from the starter switch terminal C does not flow in the safety relay, and the engine does not start.

65ZV-2 US 62-11 62 Function & Structure Electrical Group Engine Start Circuit

Starter switch

Off Enables insertion and removal of the starter key. All the electrical circuits (except the horn and hazard flasher [OPT.]) will be turned off. On Supplies power to the charge, lamp, and monitor circuits. Start Starts the engine.

Starter switch Control box

Preheat Preheats the intake air to ensure smooth starting in cold weather.

Starter switch location 85V2E62002

Preheat

35º

OFF

30º

ON 35º Start

BR R2

W3 W5

WR x 2

Preheat

WB x 2

Off

BR AC

To battery relay

BBG G

R1 BR

From battery

Connection table

BW WR WR BG WB WB

1.25

W5 W3

To neutral relay

Start

85V2E62013

65ZV-2 US 62-12 62 Function & Structure Electrical Group Engine Start Circuit

Battery relay

Alternator L terminal wire 12V

12V

30A

Battery (1)

ECM

Terminals for coil energizing current (4 mm)

Moving contact

F15

R1 BR B AC R2 C

Main contacts

(2) (3)

15A

(2)(3): Diode unit

F13

F14

10A

Suppression diode Charge circuit

Coil for energizing

Terminals for main current (8 mm)

Neutral relay

95ZV62017

When the starter switch is placed to the ON position or the start position, the battery relay is turned on. When the starter switch is set to the OFF position, the alternator stops generating power, and the battery relay is automatically turned off so that the electrical circuits will not function. If the battery relay was not used, a large amount of current would be directly sent through the starter switch when it is turned on. However, use of the battery relay reduces the amount of current because this relay needs only a small amount of current to energize it.

Battery relay operation Starter switch From charge circuit

Battery relay

To main circuit

(E)

Battery

(B)

Suppression diode

85V2E62014

Battery relay Rated voltage

DC 24 V

Minimum operating voltage

20 V or less

Release voltage

9 V or less

When current flows from the starter switch terminal AC, the coil will be energized, and the moving contact will lower to close the main contact. As a result, current will flow from the battery to the main circuit.

From alternator L terminal

65V2E62017

Engine motion-active circuit: When the starter switch is turned OFF, the battery relay is automatically turned OFF since the command current from the starter switch terminal AC stops flowing and the coil is demagnetized. Then the charging circuit from the alternator is shut down. However the alternator is still generating power and the load dump surge may be generated. This may damage the related circuits and equipment. In order to prevent this trouble, this circuit (1) is provided to hold the battery relay in the "ON" position.

65ZV-2 US 62-13 62 Function & Structure Electrical Group Engine Start Circuit

Diode unit

WV WR WP

WV:To battery relay WR:To starter switch terminal AC (VIA F15) and to ECM WP:To alternator

Diode storage section 70ZV62017

The diode unit is incorporated in the milky white connector near the battery relay. It is provided for the following purpose. 1. Diode (2) This diode is provided to prevent the roundabout current from the alternator to the ECM. If this diode is not provided (or is defective), the ECM does not turn OFF and the engine cannot be stopped. 2. Diode (3) This diode is provided to prevent the roundabout current from the starter switch AC to the alternator L terminal.

65ZV-2 US 62-14 62 Function & Structure Electrical Group Engine Start Circuit

SbP

Neutral relay

Internal connection dia. Body black 85V2E62016

Position of shift lever

Between 1 and 2

Between 3 and 4

Starting

F or R

Not energized

OFF

Impossible

Energized

Possible

The structures of the neutral relay, lift kickout relay, buzzer relay, glow lamp relay, horn relay, width lamp relay and the head lamp relay are identical to each other. Note The illustrations show the de-energized condition. When the shift lever is in the N position while the starter switch is kept at the start position, the neutral relay is magnetized and electric current flows from the battery to the neutral relay / safety relay through the starter switch terminal C.

Rating

DC 24 V

Operating voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320 

65ZV-2 US 62-15 62 Function & Structure Electrical Group Engine Start Circuit

Safety relay

Terminal S

Terminal R

B terminal C terminal

Terminal E

S.R.E terminal

Viewed from A

65V2E62003

To starter motor terminal B

From starter switch

To starter motor terminal S

From alternator terminal L

Starter relay To ground

Safety circuit

Internal circuit 65V2E62004

Safety relay voltage and current Current Voltage

Terminal S

3 A or less at 24 V

Terminal R

0.3 A or less at 24 V

Minimum actuating voltage

16 V or less

Minimum holding voltage

8 V or less

This relay receives the command to start the engine from the starter switch to operate the starting circuit. It also serves as the starter motor protection device. It prevents the starter motor pinion to engage during engine running.

65ZV-2 US 62-16 62 Function & Structure Electrical Group Power Generating/Charging Circuit

Power Generating/Charging Circuit Alternator Engine

Mechanical energy supply

Alternator

Rotor coil excitation current

Electrical energy conversion

In the electricity generated in the alternator, the voltage fluctuates depending on the number of revolutions of the engine and the load size if no measures are taken.

Generated power

<Load>

For rotor coil initial excitation

Battery

Load circuit operation

Starter switch

Voltage adjustment

Battery charge

For battery relay operation

Adjusted voltage

IC regulator

For rotor coil initial excitation

The alternator driven by the engine rectifies, with 6 diodes, full waves in three phases of the AC output generated in the stator coil by the three-phase start connection (Y connection) into DC output, then supplies it as the electric power to the battery and the machine load.

70ZV62021

The power generating/charging device and the charging circuit consisting of an alternator, regulator, battery, etc. generate and supply the power required to all electrical units of the machine.

To prevent fluctuation, a regulator is integrated so that the voltage supplied to the battery and the load circuit is always constant.

65ZV-2 US 62-17 62 Function & Structure Electrical Group ECM (Engine Controller)

ECM (Engine Controller) Function of ECM - Stops the engine. - Operates the engine. - Monitors the engine, and diagnoses it for faults.

Connection diagram ECM(V21) (V40) F36

(716) YB

B (036) G1.25

30A

(715)YL1.25

V2 V5

F15

FUEL PUMP RELAY

MAIN RELAY

WR (015)

V24

MEMORY CLEAR S/W

V81 V43 V62 V1 V3 V4

V6 (YO) (748)

V32 V7

V17

ATMOSPHERE PRESS. SENSOR INTAKE AIR TEMP. SENSOR

(VW) (765) GL (766) GyL (767) BP (768)

V61

V11

V71 V72

V21 V40

V60 V10 V8

FUEL TEMP. E/G COOLANT TEMP. E/G OIL PRESS.

GR (769) GyR (770) VR (771) Gy (772) BG (773)

BOOST TEMP.

BOOST PRESS.

GW (764) VR (774) GB (775) BLg (776)

E83 E84

V18 V37

E (013) (Lg)

(730) (BrR)

WARNING

(732) (BrW)

BOOST TEMP.

(749) E/G OIL PRESS. (Gy) (726) (BR)

GLOW LAMP RELAY

(716)

MAIN RELAY

BrG

(722)

GLOW RELAY TO CONTROLLER (E/G SPEED)

WY (758) S2H

S2H

S2L

U V W COMMON RAIL PRESS.

YR (778) YL (779)

V80 S2H

V67

V38 V74

S4W

S4B CAM ANGLE

S5S S4S S5W S5B S6S

CRANK ANGLE

−

S6W S6B

S2L

V79

V52

(YL) (747) BrG

(738)

E95

E91

E109

E94

E111

E93

E103

E92

E110

E87 E82 E90 E101

E119 E117 E116

E100

E118

E98

E120

YW1.25 (789)

YR1.25 (790)

YL1.25 (791)

E108

E106

E105 E113 E89 E97

EGR

RG1.25 (794) LgBr

(792)

CYLINDER1

LgW

(793)

CYLINDER4

RG1.25 (797) LgR

(795)

CYLINDER2

LgY

(796)

CYLINDER3

E99

E107

DATA LINK CONNECTOR

E121 S4R

CAN

S2S

EGR POTENTIOMETER

YW (777)

F13

GyR (798)

SCV

GyB (799)

E/G

E/G ECM connection diagram 65V2E62013

65ZV-2 US 62-18 62 Function & Structure Electrical Group ECM (Engine Controller)

Monitor lamp test

ON Key switch OFF

Approx. 2 sec

ON Boost temp. rise lamp

Yellow

OFF

Lights when abnormality occurs.

ON Engine error warning lamp OFF

Red

70V2U62010

(S/N 5001~5400)

(S/N 5401~)

STOP

Engine warning lamp Engine stop lamp 65V2U62008

When the starter switch is set to ON, two engine monitor lamps (engine error warning and boost temperature rise) are lit for approximately 2 seconds. After that, if there is an abnormality in a circuit, a corresponding monitor lamp lights.

65ZV-2 US 62-19 62 Function & Structure Electrical Group ECM (Engine Controller)

Diagnosis trouble code (DTC) information These codes show the fault codes for the engine failure displayed on the MODM error log monitor. These codes are also quickly retrievable with Isuzu EMPS3 hand held analyzers. DTC LAMP

Error

87 Red

No pump pressure feed (fuel leakage)

88 Red

Common rail pressure fault

89 Red

Common rail pressure fault (Excessive pressure feed in pump)

90 Red

SCV drive system open circuit +B short or ground short

107 Red

Barometric pressure sensor fault (low voltage fault)

108 Red

Barometric pressure sensor fault (high voltage fault)

112 Red

Intake air temperature sensor fault (low voltage fault)

113 Red

Intake air temperature sensor fault (high voltage fault)

117 Red

Engine coolant temperature sensor fault (low voltage fault)

118 Red

Engine coolant temperature sensor fault (high voltage fault)

182 Red

Fuel temperature sensor fault (low voltage fault)

183 Red

Fuel temperature sensor fault (high voltage fault)

192 Red

Common rail pressure sensor fault (low voltage fault)

193 Red

Common rail pressure sensor fault (high voltage fault)

201 Red

Open circuit in injection nozzle #1 drive system

202 Red

Open circuit in injection nozzle #2 drive system

203 Red

Open circuit in injection nozzle #3 drive system

204 Red

Open circuit in injection nozzle #4 drive system

205 Red

Open circuit in injection nozzle #5 drive system

206 Red

Open circuit in injection nozzle #6 drive system

219 Red

Engine speed abnormally high

237 Red

Boost pressure sensor fault (low voltage fault)

238 Red

Boost pressure sensor fault (high voltage fault)

335 Red

Crank sensor fault

65ZV-2 US 62-20 62 Function & Structure Electrical Group ECM (Engine Controller)

DTC LAMP

Error

336 Red

Crank sensor fault

340 Red

Cam sensor (G sensor) fault

341 Red

Cam sensor (G sensor) fault

380 Red

Glow relay fault

381 Red

Glow plug lamp circuit fault

487 Red

EGR position fault (Brushless specification)

488 Red

EGR valve control fault

522 Red

Engine oil pressure sensor fault (low voltage fault)

523 Red

Engine oil pressure sensor fault (high voltage fault)

601 Red

ROM fault

603 Red

EEPROM fault

606 Red

CPU fault

611 Red

Charge circuit fault (bank 1)

612 Red

Charge circuit fault (bank 2)

650 Red

Diag. lamp circuit fault

1093 Red

No pump pressure feed (fuel leakage)

1095 Red

Pressure limiter is opened

1112 Red

Boost temperature sensor fault (low voltage fault)

1113 Red

Boost temperature sensor fault (high voltage fault)

1173 Red

Overheat

1261 Red

Injection nozzle common 1 drive system fault

1262 Red

Injection nozzle common 2 drive system fault

1271 1277 1278 1282 1283

Accelerator sensor 1-2 comparison fault Accelerator sensor 1 fault (low voltage fault) Accelerator sensor 1 fault (high voltage fault) Accelerator sensor 2 fault (low voltage fault) Accelerator sensor 2 fault (high voltage fault)

1294 Red

Fuel filter sensor fault (high voltage fault, short circuit, ground disconnection)

1345 Red

Cam sensor out of phase

65ZV-2 US 62-21 62 Function & Structure Electrical Group ECM (Engine Controller)

DTC LAMP

Error

1625 Red

Main relay system fault (Not enter)

1630 Red

A/D conversion fault

1631 Red

Voltage fault i 5-V power supply 1

1632 Red

Voltage fault i 5-V power supply 2

1633 Red

Voltage fault i 5-V power supply 3

1634 Red

Voltage fault i 5-V power supply 4

1635 Red

Voltage fault i 5-V power supply 5

2104 Red

CAN Bus fault

2106 Red

CAN time-out fault

65ZV-2 US 62-22 62 Function & Structure Electrical Group ECM (Engine Controller)

Accelerator pedal

Pedal

BY (114)

Throttle opening sensor

A-Black-APS signal B-White-APS ground C-Red-APS supply (5 V) D-Green-Throttle active E-Blue-Idle active F-Orange-IVS supply (5 V)

E07

S3B S3W

C18

S3R

[MCU] (E09)

V (100)

W (161)

ECM (V8)

E15

Note APS-Acceleration Position Signal IVS-Idle Validation Switch

Circuit diagram

Connector (G) 6 (L) 5 (O) 4

1-Black-APS signal 2-White-APS ground 3-Red-APS supply (5 V) 4-Orange-IVS supply (5 V) 5-Blue-Idle active 6-Green-Throttle active

1 (B) 2 (W) 3 (R)

A View A

65V2E62025

Note Potentiometer voltage (V)

Pedal Test Typical pedal potentiometer resistance at 18ºC (65ºF). Wire colors are at the pedal harness with accelerator pedal unplugged.

Input

Wire colors

 at pedal up position

Up position

3.75~3.95

R-B

1,540~2,310

 at pedal down position 260~390

Down position

0.55~0.75

W-B

260~390

1,540~2,310

R-W

2,000~3,000

G-O

Open

L-O

Open

65ZV-2 US 62-23 62 Function & Structure Electrical Group ECM (Engine Controller) When the accelerator pedal is pressed, the voltage corresponding to the pressing angle is input as a signal from the potentiometer to the MCU, and it transfers to the ECM (engine controller) to control the engine revolution.

Pedal stop

Stroke

K65V2U62004

Pedal angle

Note Part “A” is added on S/N 5201 and thereafter and force on pedal is increased from 50 N (5.1 kgf) (11.2 lbf) to 77 N (7.9 kgf) (17.3 lbf).

Installation angle 45

Pedal Angle

Between terminal C18(W) and E07(B) Refer to circuit diagram for details.

Potentiometer Voltages when plugged in, key "ON"

5V 4 3 2 1 0

0 Pedal Angle

85V2E62019

65ZV-2 US 62-24 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Transmission Control Circuit and Monitor Circuit Machine control unit (MCU)

To S5

To S6

To S7

To S8

To S9

85V2E62041

65ZV-2 US 62-25 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Connector

MCU

To S5

To S6

To S7

To S8

To S9

C 1.2S_SE C 2.POD_SW1 C 3.POD_SW2 C 4.DSUB4 C 5.TT C 6.AC C 7.ET C 8.BL C 9.BD C10.DSUB1 C11.HYDOL C12.DR C13.BSL_S C14.TF C15.WL

C16.EP C17.F C18.ASUB1 C19.TEMP_SE C20.1/2 C21.1/8 C22.2S C23.EGM C24.IP_SW C25.FR C26.KO_P C27.ES_SE C28.3/4 C29.1/4 C30.DC

MCU A 1.2S_SO A 2.2_SO A 3.ES_R A 4.DD_SO A 5.3_SO A 6.HM A 7.LU_SO A 8.4_SO A 9.EG_SW1 A10.R_L A11.F_L A12.ST_L A13.WL_L A14.CW_L A15.ET_L

A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.SS_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

A31.1/4_L A32.FR_L A33.3/4_L A34.EG_SW3 B 1.H_SO B 2. B 3.IP_SO B 4.R_SO B 5.MO_SO B 6.FR_SO B 7.SSL_SO B 8.ISW_R B 9.BZ B10.BSL_R B11.KO_R

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

A27

A28

A29

A30

A31

To S5

A32

A33

A34

B12.X_R B13.F_SO B14.B_SO B15.EG_SW2 B16.RIN1 B17.OUT_MD2 B18.N_R B19.BR_L B20.CAN_R1 B21.CAN_R2 B22.DOUT1 B23.OUT_FEW B24.MT B25.ET_SE B26.TXD1

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

B21

B22

B23

B24

To S6

B25

B26

E 1.SSR_SO E 2.FC_SO E 3.KEY E 4.KEY E 5.GND E 6.GND E 7.GND E 8.GND E 9.+5V E10.TGEG E11.KEY E12.KEY E13.CANH1 E14.EGR2 E15.EGR1

E16.SPD E17.BATT E18.CANL1 E19.SS_P E20.CANLO E21.TM_M E22.B_SE2 E23.WT_SE E24.ALT E25.RXD1 E26.TGSP E27.INCH_SE E28.ASUB2 E29.CANHO E30.B_SE1

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E10

E11

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E26

E27

E28

E29

E30

E31

E32

E33

To S7

E34

C31.BSL C32.DSUB3 C33.DD_S C34.AFR D 1.PRK D 2.AM_SW D 3.SL_2 D 4.SL_R D 5.SL_3 D 6.S_UP D 7.S_DOWN D 8.EG_SW D 9.M_SW D10.SL_1 D11.SL_F

C10

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C26

C27

C28

C29

C30

C31

To S8

C32

C33

C34

D12.SL_A D13.DSUB2 D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

D21

D22

D23

D24

D25

D26

To S9

Connector details 65V2E62014

65ZV-2 US 62-26 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) connection diagram (S/N 5001~5400)

ACC’

(L) (005-b) (005) L2

TO PARKING S/W

(L) (005-a)

30A G (010)

F10

Lx4 (005-A~005-D)

ACC’ E05 E06 E17 WL (707)

E24

E04 E12 E03 E11 B18 B12

LR (126) LBr (128)

23A

B10

LW (120)

LY (121) YO (232) YW (233) R

LgW (101) BrB (258) L

(273)

NEUTRAL RELAY

MCU FAILURE RELAY

LIFT KICK OUT RELAY LOWER KICK OUT RELAY

BS OPT

B13

LG (122)

F/R SELECTION S/W

B11

A03

LO (123)

D04

SHIFT LEVER

F N R

D11

(SbP) (145)

YGy (242)

SECONDARY STEERING MOTOR RELAY COIL

LR (146)

F SOLENOID VALVE

D12 D05

B04

D03 D10

A18

LBr (148)

R SOLENOID VALVE

(141) LY

1ST SPEED SOLENOID VALVE

(LY) D19 A02

(142) LG

2ND SPEED SOLENOID VALVE

D26 (LG) D06

A05

(143) LO

3RD SPEED SOLENOID VALVE

D07 (LO)

SHIFT INPUT SELECTION S/W

YV (231)

ARM WREST S/W

D18

A08

(144)(LW)

4TH SPEED PILOT LAMP

D24 (YL) (124) (YL) (124)

DOWNSHIFT S/W

YSb (125)

SHIFT HOLD S/W (OPT)

LP (168)

DECLUTCH SET-UP

(210)

LIFT KICK OUT SET-UP

BrG (255)

LOWER KICK OUT SET-UP

BW (271)

F13 DECLUTCH

(013) (Lg)

Lg (222) LgY (223) (Y) (105) (R) (106)

SPARE OPTION 1 OPTION 2 A/M SELECTION ODOMETER SELECTION SPEED SENSOR SELECTION METER SELECTION

P (107) PL (108) PG (109) PB (110)

LgG

LLg (165) GO (164)

DECLUTCH (163) (SbW) (005-b) (L)

OFF

E/G OIL PRESS. S/W F5

PARKING S/W

A04 A01

C13 B06

C25 E02

C30

BrY (181)

HYD. OIL LEVEL S/W

LgL (182)

AIR CLEANER CLOGGING S/W

RIDE CONTROL SOLENOID VALVE (OPT) EFFICIENT LOADING SYSTEM SELECTION SOL. VALVE (OPT)

GB (267) LgL (225) (221) LgB

REVERSAL FAN SOL. VALVE (OPT) (226) LgB

FAN SPEED CONTROL SOL. VALVE

1A E01

C12 C02

B07

C03 F13

D02 D16 A21 A29 A14 D21 A28 D01 A19 A15 A16 A27

Gy (750)

LgL (261)

C34

GyW (200) C23 GL (265) GL (265) C22 GyW (260) C33

OFF ON

D22

A07

D09

PARKING SOL (162)

D23

D08

(LgY) (167)

D15

D25

YO (176)

DECLUTCH S/W

B14 D17

C31

LOWER KICK OUT S/W REVERSAL FAN S/W (OPT) AUTO FAN REVERSAL S/W (OPT) SPARE

A17 D14

C16

A12

C11

A20

C06

A30

(LgR) (130) (GR) (135) (GyB) (103) (LgY) (173) (O)

(013) (Lg)

AUTO SHIFT INDICATOR LAMP NEUTRAL INDICATOR LAMP CENTRAL WARNING LAMP BRAKE OIL PRESS. WARNING LAMP

(241)

(GyG)(753)

E/G COOLANT TEMP. WARNING LAMP

(GyL) (190)

T/M OIL TEMP. WARNING LAMP

(LgW)(192) (O) (241)

AIR CLEANER WARNING LAMP STEERING OIL PRESS. WARNING LAMP

FUEL EFFICIENT MODE S/W

E EFFICIENT LOADING SYSTEM S/W (OPT)

RIDE CONTROL S/W (OPT) X

MCU FAILURE

FUEL LEVEL GAUGE

(LgW)(102)

(404)(YBr) (LgSb)(112)

WARNING BUZZER

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information. K65V2U62001

65ZV-2 US 62-27 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

C09

A32

C08

A24 B09

V (100)

E09 (+5V)

TO E/G SPEED SENSOR TO THROTTLE SENSOR

E34 E19 E21

BOOM ANGLE SENSOR

BrR (251)

DECLUTCH SENSOR

LgR (166)

BRAKE OIL PRESS. SENSOR 1

C26 B24 E27

SbY (171) E30 E10

BRAKE OIL PRESS. SENSOR 2

SbY (172) E22

SECONDARY STEERING OIL PRESS. SENSOR (OPT)

E26 SbR (240)

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR (OPT)

GyG (754) GyL (180)

T/M OIL TEMP. SENSOR

(G) (415)

AIR TEMP. PROBE

GyO (220)

HYD. OIL TEMP. SENSOR

A06

B25

A10

E31

B19

(E09)

B23(OUT_FEW) E33(OUT_RES) E25(RXD0) B26(TXD0) B17(OUT_MD2)

S3B

ECM(V8)

MACHINE SPEED SENSOR

(DOUT1)B22

Y (159)

T/M OIL TEMP. GAUGE

(400) (WL)

METER OUTPUT (TACHOMETER)

(420) OL (420) (+) OL

(−)

(421) OB (+)

(−)

TACHOGRAPH E/G SPEED (OPT) TACHOGRAPH GROUND SPEED (OPT)

YSb (403) (LB) (138) (RG)(331)

HOUR METER DRIVE TO BACK-UP LAMP TO BRAKE LAMP E (100) V

(115) (YB) (116) (YG) (117) (YL) (118) (YO) (119) (YBr)

+5V FEW RESET RXD TXD MD2 GND

MCU PROGRAM REWRITE

E (RIN1)B16

Y (160)

E/G COOLANT TEMP. GAUGE

(BrW) (402)

C18

V (100)

W (161)

BUZZER

(YB ) (401)

S3R

E/G SPEED SENSOR

S/S INDICATOR LAMP BZ

(E09) E23 E07

S3W

LgBr (104)

E32

BY (114)

THROTTLE OPENING SENSOR

(LgB) (224)

C27

GyB (266) C01

E/G COOLANT TEMP. SENSOR

REVERSAL FAN INDICATOR LAMP (OPT)

(RL)(235)

E15

(CANH0)E29 (CANL0)E20

E16

GL (810)

RS232C

GR (811)

S2H S2L

S2H

E08

S2L

MAIN MCU

CAN

S2S

K65V2U62002

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information.

65ZV-2 US 62-28 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) connection diagram (S/N 5401~)

# # #

$ $

/ +- / "+

$ ( $ $ $ #

,- + - " + +- / "+ + / "+

$ ,- + /

,- + , $ / "+

$ + , + "

$ 1 23345 1 643

/ +- $ + +-

$ + ,

" $ +- + +-

# % #

+ - + + "

$ + , /

" -

" - /

/ - " 0 / , $0 - / - - /

$ $ # $

% %

" ( $ " $ $ $ $ ( % $ $

& ' $

!" %

+ - - + - + - +

)

$ + - + - "+ -$ -$ + " $ -$ + " $ " $ " $ -$

$ " $ " $ " $ -$

$ " $ "

+, " $ "- + "

- + - + + " - + + " - + / / "+ + / - ,- +- $ +- "+

+ " - /

$ $ $ $

,- +

# #

-$ + -$ "+ - - + $- + +- 0 "+ 0

% # % %

" $ + 0

( ( ( #

% % % # # ( % (

** + ,- + - $- + " + - $- + " + - " - " 0 - " / + + "0 - " +/ - + "0 - " - - " + - - " 0 - "

(

- - + $ /

67823 83

- - + $- + / -$ + -

- **

)

% !

/ - + + " *

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information.

65ZV-2 US 62-29 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

& &

+ * ! ' % &

! ' & ( * , & ( * ,

+ & %*, +% ( %*, &( %*, * ' !, ( %*,

%& '(

* !

+ & %*, &

+% ( %*, &

% * & ' %

' % ! (

- * &%* & &

# $ "! "! %!

' * (

!& ( ( * , * ##( ( &!( % ( * , *

+ *

& #& ( !( & &%* + ( !( & &%* *

( !

# $ "! "! %! !

% * &% $ (

' & ' & '

& ./012 02

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information.

65ZV-2 US 62-30 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) function Forward/reverse (F/R) shifting and speed change

From T/C pump F/R clutch solenoid valve

N R

+24 V

Shift lever

Clutch pressure regulator valve Surge suppression diode (incorporated in solenoid valve)

Speed clutch solenoid valve

A 23

To solenoid valve bank

Clutch piston Speed indicator lamp (instrument panel)

Downshift button

MCU

+24 V

2 Drain

Clutch control solenoid valve

3/4 energized de-energized

Speed sensor

clutch engage clutch disengage

+24 V

AUTO indicator lamp ON when shift lever in A position

65V2E62007

Each clutch has one solenoid valve for transmission control. When electric current flows through the solenoid valve, the clutch oil is fed into the clutch piston chamber. When the piston operates, the clutch is engaged. When the current stops flowing through the solenoid valve, the oil is drained from the clutch piston chamber, and the clutch is disengaged. The solenoid valve for the 4th speed clutch is not installed on the transmission. When the current stops flowing to all solenoid valve for the 1st, 2nd and 3rd clutches, the transmission is automatically engaged to the 4th speed. Input detection When the shift lever is set to the F (forward) position, electric current for input detection signal is sent from the MCU to the grounding circuit via shift lever contact F. The MCU, therefore, judges that the shift lever is set to the F (forward) position. On the other hand, there is no shift lever contact for the R (reverse) input circuit and no electric current will flow to the ground circuit.

For the speed change, the MCU judges the set speed position of the shift lever in the same way as described above. Operation error preventive function (Simultaneous input of two or more commands) If both the forward and reverse commands are input at the same time due to a problem, the forward and reverse clutches will not function. In addition, if two or more speed commands are input at the same time, the machine will stay engage in the gear just before the shift lever stuck and still move with it’s gear selection. When the starter switch is at OFF position, if both the forward and reverse commands are input at the same time due to a problem, the engine does not start even if the starter switch is placed in the start position. This is because the neutral relay does not work.

65ZV-2 US 62-31 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Shift lever

KNIGHT BEAM CO,LTD BM51-111 JAPAN >PAMXD6-G50<

Forward F

Neutral N

Reverse R

1st speed

2nd speed

3rd speed Auto

Grounding for speed change side (B) 1st speed (GW)

2nd speed (GL)

Auto (G)

3rd speed (GY)

F (GR)

Unused

R (GB)

Grounding for F/R side (B)

70ZV62025

1. Bracket assembly 2. Grip 3. Connector

Operator controlled shifting from 2  1  2 in either "2" or "A" is done by momentarily depressing the downshift button on the boom lever.

The shift lever has two direction and four speed positions; forward and reverse (F and R) and "1", "2", and "3" speed positions are respectively used for 1st, 2nd, and 3rd fixed speeds. The "A" speed position is used for the variable speed where the 2nd through 4th speed clutches are automatically changed in both the forward and reverse operation.

Shift lever neutral (N) position The shift lever has no neutral (N) contact. Therefore, if neither the forward nor the reverse (F and R) signal is input, the MCU will judge that the shift lever is at the neutral (N) position.

65ZV-2 US 62-32 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Automatic shift

Operation of solenoid valve Clutch solenoid valve (Common to F·R·1·2·3/4)

Shift up

Shift down

Speed

Positive side

3 Negative side

17.0 14.0 10.5 8.5 (10.6) (8.8) (6.6) (5.3)

Reverse

9.0 11.0 (5.6)(6.9)

14.5 17.5 (9.1)(10.9)

Speed km/h (mile/h) Automatic shift map (standard value)

Solenoid valve (with built-in diode) Rated voltage

DC 24 V

Coil resistance value

Approx. 31 

When the input signal is transmitted, the output circuit of the corresponding solenoid valve is connected to the grounding circuit. As a result, power is supplied to the solenoid valve and the clutch is engaged. At the same time, the speed indicator lamp in the cab lights. Note that when the parking brake or inching brake is applied, the forward or reverse (F or R) clutch solenoid valve is turned off and the transmission is set to neutral.

Forward 70V2U62006

When the shift lever is set to A, the AUTO indicator lamp in the cab will light and one of the 2nd through 4th speed solenoid valves will be automatically energized according to the machine speed. In addition, the speed indicator lamp will light. The input signal for automatic shift is controlled by the pulse generated by the speed sensor.

65ZV-2 US 62-33 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine speed sensor

19 mm (0.75 in)

49 N-m (5 kgf-m) (35 lb-ft)

Clearance adjustment 0.5~1.1 mm (0.02~0.04 in) K70ZV62010

Internal resistance *

700  (25ºC) (77ºF)

* Internal resistance changes greatly with temperature. At lower temperature resistance is lower. At operating temperature the resistance increases. If resistance is 0  or   the speed sensor is defective.

The detector is adjacent to the transmission output gear. The pulse voltage is transmitted to the MCU. Note To prevent electronic "noise" from other sources that may corrupt signal, "twist" the wire from sensor all the way to the MCU.

IMPORTANT Make sure to apply the correct torque value when replacing the sensor. Shims help to set clearance between sensor & gear but over-torque can change clearance.

65ZV-2 US 62-34 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Switching from automatic to manual

Downshift button operation

Downshift button

LgL SbY GR A502 A507 A701

A/M SELECTION B PG S902 1

SbLg A608

SbL H718

GR T103

LY Gy Gy LP LgB A708 A506 A807 A808 A604 H201 RL GyB GyG GyL LP 0 H128 A809 A505 A501 H207 A609 T801 GB LG YGy LgSb LO YSb LLg LW SbP H121 A709 E804 H122 A710 A901 H110 A711 F202 H204 H202 H203

SbP RG F701 H139

SbR LgBr L BrB LgW LR F102 G602 T001 T901 F901 H205 LBr H206

WL GyG A806 H136

WO SbW GL H117 H703 T104

LgL BL E502 E001

(BLACK) S4

85V2E62025

The machine has automatic shift cancellation function for troubleshooting. Connect the coupler (OPT) to S4 coupler to cancel the automatic shift function. The mode will be switched from automatic to manual. Position "A" of the shift lever, therefore, is fixed to the 4th speed.

65ZV62021

The downshift button is attached to the boom control lever. In any operation mode, pressing the downshift button during 2nd speed operation shifts the 2nd speed to the 1st speed. After that, if the downshift button is pressed again, the speed is changed from the 1st to the 2nd, or to move the shift lever to neutral or to the opposite direction, the speed will be changed to the 2nd again. Note that when the speed is shifted, the transmission status monitor lamp on the instrument panel changes from the 2nd gear to the 1st gear or from the 1st gear to the 2nd gear. Downshift button

70ZV62031

Allowable value

Max. voltage

DC 24 V

Current

10 mA

The downshift button is of the momentary type. It is spring loaded to the "OFF" position.

65ZV-2 US 62-35 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Adjustable declutch preset switch 200

Clutch OFF

Clutch ON

310

510

(kPa)

Declutch sensor

85V2E62028

Declutch preset switch ON

Declutch sensor

Transmission clutch

More than 510 (kPa)

Disengage

Less than 310 (kPa)

Engage

Adjustable declutch preset switch is used to change the angle of the brake pedal to disengage the transmission clutch. Declutch sensor

With the engine running, step on the brake pedal up to the desired angle and press the switch to set the brake pedal angle. 85V2E62006

Hold

Reset

switch-5

Switch

65V2U62005

65ZV-2 US 62-36 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Right brake pedal (brake only pedal) MCU Forward/reverse clutch solenoid valves F R

D21

Micro switch for declutch

85V2E62026

Brake pedal (right)

8.5 FP

Micro switch COM

L=200 50

05R0

CA001

05R0

CA001

Minimum application load: DC 5 V 160 mA

COM 85V2E62004

When the right hand brake pedal is pressed and the declutch selector switch on the instrument panel is ON, the declutch pressure sensor installed on the left brake valve signals the MCU to turn off the F or R solenoid. As a result the transmission is disengaged. This micro switch prevents the right hand brake pedal from disengaging the transmission. Pressing the right hand brake pedal actuates the micro switch (declutch switch), turns off the power to the MCU. Even when the declutch selector switch on the instrument panel is ON, this micro switch leaves the F or R clutch engaged. As a result, the right brake pedal works as a brake only pedal.

NC 85V2E62005

OF (Operating force)

max.

130 gf (0.3 lb)

RF (Return force)

min.

21 gf (0.05 lb)

OT (Operating distance)

min.

4 mm (0.157 in)

MD (Moving distance)

max.

1.6 mm (0.063 in)

FP (Free position)

max.

36.5 mm (1.437 in)

OP (Operating position)

30.2±0.8 mm (1.189±0.031 in)

65ZV-2 US 62-37 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Back-up alarm

Back-up lights

Shift lever

Back-up alarm

MCU

+24 V

2 3

A10

85V2E62027

When the shift lever is set to the reverse (R) position, the back-up lamp will light, and the buzzer will sound.

65ZV-2 US 62-38 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Parking brake

5A F13

+ 24V

Monitor lamp

Parking (ON)

Parking brake Cylinder

Running (OFF) Parking switch ON OFF MCU

D01

30A F5 + 24V

85V2E62029

The parking brake solenoid valve activates the parking brake. Parking switch ON:

Parking switch OFF:

When the power of the solenoid valve is turned off, no oil will be fed to the oil cylinder. The spring inside the cylinder applies force to make the brake apply (drum type). If the transmission shift lever is set to the forward or reverse (F or R) position, the buzzer will sound and the clutch will not be engaged.

When the power of the solenoid valve is turned on, oil will be fed into the oil cylinder. The oil will depress the spring to release the brake.

Parking brake operation Parking switch

Monitor lamp

Buzzer

Parking brake solenoid valve

Parking *

"Parking" position (pulled up)

Sounds when shift lever is set to F or R

No electric power supply

Running

"Running" position (pushed in)

Off

No buzzer

Electric power supply

*When the parking switch is set to "parking", the forward or reverse clutch is disengaged and set to neutral.

65ZV-2 US 62-39 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Solenoid valve for parking brake Spring chamber (brake actuator) B

Reducing valve

Solenoid

Knob

T Seat face A

Manual release (counterclockwise rotation)

Spool

Seat face B Tank

115V2E62020

Solenoid specifications

Rated voltage

DC 24 V

Rated current

0.92 A

Resistance

26.2 

Hydraulic circuit diagram

95ZV52045

Valve assembly

Solenoid valve for parking brake

Rear chassis Installation position 65V2E62008

65ZV-2 US 62-40 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) failure warning Should the MCU stop working due to the following cause, a dash mounted monitor lamp lights up to give warning. MCU failure monitor lamp

MCU replacement If the monitor lamp lights up under the cause above, it is an indication that the MCU's program has malfunctioned and the MCU assembly must be replaced.

Electric circuit

LgW

The MCU has a self-diagnosis function incorporated in it, and if the computer program becomes abnormal due to abuse or defect, a dangerous condition may occur, the monitor lamp lights up and all the outputs from the MCU are turned OFF.

LgW

Body blue

If a warning is given as a result of self-diagnosis of the MCU

Chassis side coupler

When installing a new MCU on the machine, all specifications must be registered into the MCU through the MODM.

85V2E62030

Rating

DC 24 V

Operation voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320 

MCU fault relay (Normally closed)

65ZV-2 US 62-41 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Secondary steering function (OPT)

Speed sensor Pilot lamp

To priority valve

F13 MCU

To loading line Pressure sensor

Check valve

Check valve G1 G1/2

+24 V

Secondary steering motor and pump

G1 G1/2

10 cm3/rev

G3/8

11.7 MPa (119.3 kgf/cm2) (1,696 psi)

To brake and pilot line

45.6 26.7 14.2 cm3/rev cm3/rev cm3/rev

G1/4 TS

Magnetic switch (on motor and pump)

Hydraulic line Electrical circuit

Steering pump

65V2E62009

With some problems, as the steering hydraulic pressure goes down while the engine is running, the pressure sensor signal becomes less than the preset value at the MCU. In this condition, if the machine speed is more than 2 km/h, the MCU sends a signal to the magnetic switch. As a result, the secondary steering motor and pump is driven. Then it is ready to steer the machine.

Machine speed signal

The signal from MCU to magnetic switch

In normal operation, the oil from the steering pump flows into the priority valve through the check valve. And the signal of the pressure sensor is always sent to the MCU.

Machine speed

OFF

(km/h)

85V2E42051

Pressure sensor preset value Steering hydraulic pressure ON: at 0.3 MPa (3 kgf/cm2) (44 psi) or lower OFF: at 0.4 MPa (4 kgf/cm2) (58 psi) or higher

65ZV-2 US 62-42 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Monitoring system If a problem of a unit is detected while the engine is running, a monitor lamp lights to inform the operator.

When the starter switch is set to ON, all of the monitor lamps are lit for 3 seconds and buzzer sounds to check whether the monitor lamps are normal (not burn out).

For some problems, the buzzer sounds also, and the central alarm lamp flashes also.

Items to be monitored and operation condition Monitor lamp No.

Item to be monitored

Machine control unit (MCU)

Lighting color

Defective machine control unit (MCU)

Brake oil pressure

Engine oil pressure (red)

Engine water temperature (red)

Torque converter oil (transmission) temperature

(red)

Clogged air cleaner (red)

Buzzer

Lamp test

Remarks

—

(red)

(red) 3

Operation condition Symbol

Charging condition

Unloader valve accumulator port oil pressure is lower than 3.9±0.5 MPa (40±3 kgf/cm2) (569±71 psi) While engine running, 48 kPa (0.5 kgf/cm2) (7 psi) or less for more than 0.5 second 101±2ºC or more (214±4ºF or more) for more than 2 seconds

—

120±5ºC or more (248±9ºF or more) for more than 2 seconds

—

Filter resistance: 635±58 mmAq or more (25 inches H2O) for more than 2 seconds

—

Defective charge system

—

For items 1~6, 9

—

(red) 8

Central alarm

Flashing type

(red) 9

Steering oil pressure (option)

(red)

(red) 10

Hydraulic oil level

When operates steering pressure is less than 0.4 MPa (4 kgf/cm2) (57 psi), machine speed more than 2 km/h

Hydraulic oil level is low when the engine is stopped

(red) 11

Engine warning lamp (Boost temp. rise)

(yellow)

Boost temperature is 85ºC (185ºF) or more for 1 second

—

Any fault in engine detected by ECM (Engine controller)

—

(2 sec.) 12

Engine warning lamp (Error warning)

(red)

65ZV-2 US 62-43 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Operation monitor lamps Monitor lamp No.

Monitor item

Lighting color

Lighting condition

Remarks

Symbol

Parking

Red

When parking brake switch is set to ON

Declutch

Green

When declutch selector switch is set to ON

Working light

Green

When working light (rear) switch is set to ON

Preheat

Yellow

When starter switch is in the PREHEAT position

Turn signal indicator (left)

Green

When turn signal lever (left) is actuated

Turn signal indicator (right)

Green

When turn signal lever (right) is actuated

High beam

Blue

When head lamp is set to high beam

Auto shift

Green

When transmission shift lever is set to automatic position

Neutral

Green

When transmission shift lever is set to neutral position

Transmission status

Yellow

When transmission shift lever is set to corresponding gear (1~4)

Caution on storage of individual instrument panel

IMPORTANT

Gauge pointer

Pointer axis Axis hole

When storing the instrument panel individually, make sure that the panel face (transparent face) faces upward. If the panel face faces below the vertical direction, the damper oil may leak from meter pointer axis holes.

Main body frame

Meter

Damper oil

Magnet

70ZV62039

65ZV-2 US 62-44 62 Function & Structure Electrical Group Instrument Panel and Switch

Instrument Panel and Switch Instrument panel (S/N 5001~5400)

19 5 18

11(28) 12

13 34

STOP

15 16 27

26 24 22 (28)

65V2U62006

1. Tachometer 2. Engine coolant temperature gauge 3. Torque converter oil temperature gauge 4. Fuel gauge 5. Parking brake indicator lamp (red) 6. Declutch selector indicator lamp (green) 7. Working light indicator lamp (green) 8. Preheat indicator lamp (orange) 9. Central warning lamp (red) 10. MCU (Machine control unit) warning lamp (red) 11. Brake pressure warning lamp (red) 12. Engine oil pressure warning lamp (red) 13. Engine coolant temperature warning lamp (red) 14. Torque converter oil temperature warning lamp (red) 15. Air cleaner warning lamp (red) 16. Charge lamp (red) 17. Turn signal indicator lamp (left) (green) 18. Turn signal indicator lamp (right) (green) 19. High beam indicator lamp (blue) 20. Auto shift indicator lamp

21. Neutral indicator lamp 22. Transmission status monitor 23. Hour meter 24. Secondary steering warning lamp (red) (option) 25. Engine warning lamps 26. Reversal fan pilot lamp (green) (option) 27. F/R switch indicator lamp (green) 28. Hydraulic oil level warning lamp (simultaneous flashing) (red) (11. 24) 29. Working light switch (front) 30. Working light switch (rear) 31. Fuel efficient mode switch 32. Four-way flasher switch (option) 33. Efficient loading system switch (option) 34. Selection switch for shift lever or F/R switch (option)

65ZV-2 US 62-45 62 Function & Structure Electrical Group Instrument Panel and Switch (S/N 5401~)

20 17 19

9 5 37 7 18 2 4

11(34) 10

32 33 (36)

25(34)

6(35)

23 8

3 13 14 15 16

31 30 K70V2U62004

1. Tachometer 2. Engine coolant temperature gauge 3. Transmission oil temperature gauge 4. Fuel gauge 5. Parking brake indicator lamp 6. F/R switch indicator lamp (option) 7. Working light indicator lamp (rear) 8. Preheat indicator lamp 9. Central warning lamp 10. Machine control unit (MCU) warning lamp 11. Brake oil circuit warning lamp 12. Engine oil pressure warning lamp 13. Engine coolant temperature warning lamp 14. Transmission oil temperature warning lamp 15. Air cleaner clogging warning lamp 16. Charge warning lamp 17. Turn signal indicator lamp (left) 18. Turn signal indicator lamp (right) 19. High beam indicator lamp 20. Auto shift indicator lamp

21. Neutral indicator lamp 22. Transmission status monitor 23. Hour meter 24. Reversal fan pilot lamp (option (S/N ~5350)) 25. Secondary steering warning lamp (option) 26. Working light switch (front) 27. Working light switch (rear) 28. Fuel efficient mode switch 29. Four-way flasher switch (option) 30. Engine warning lamp 31. Engine stop lamp 32. Efficient loading system switch (option) 33. Selection switch for shift lever or F/R switch (option) 34. Hydraulic oil level warning lamp 35. K-Lever indicator lamp (green) (option) 36. K-Lever switch (option) 37. Declutch selector indicator lamp

65ZV-2 US 62-46 62 Function & Structure Electrical Group Instrument Panel and Switch

Instrument panel rear surface (S/N 5001~5400) CN4 CN1

1 5 L2

58 57 L14 Hour meter

L10

12P

L20

L10

S L21

L16 L10

L17 V E Engine water temp. sensor

Fuel gauge

S V

56 L10

L15

16P

L10

L3 L4

CN3

L12

L13

L11

L18

L10

L19

L8 E V T/M oil temp. sensor

CN2

L22

L23

L24

L25

L26

L27

20P 19

Layout of connector pins (Instrument panel side)

Pin No.

CN1(8P)

CN2(20P)

9 10 11 12 13 14 15 16 17 18

29 30 31 32 33 34

41 42 43 44

19 20

35 36 37 38 39 40

49 50

3 4

6 7

22 23 24 25 26 27 28

Signal

Lamp No.

Pin No.

—

CN3(12P/16P)

Charge lamp

Air cleaner clogging alarm

T/M oil temperature alarm

Engine water temperature alarm

Engine oil pressure alarm

Brake oil pressure alarm

8 9

Signal

CN4(2P) A8

Lamp No.

A9 46 47 48

53 54 55 56

58 57 85V2E62033

Pin No.

Signal

Lamp No.

—

L16

—

Converter (+)

—

Converter (–)

—

Declutch lamp

L17

—

Preheating lamp

L19

MCU failure alarm

GND (–)

—

Work lamp

L18

+24 V power supply

—

+24 V power supply

—

Central alarm lamp

L14

GND (–)

Fuel gauge (sensor)

AUTO lamp

L20

—

Secondary steering (optional)

L22

—

Reversal fan (optional)

L23

—

Engine warning lamp

L25

—

L24

—

High-beam lamp

L12

—

— — —

Engine warning lamp

L26

Neutral

L21

Turn signal (left) lamp

L13

F/R switch indicator

L27

GND (–)

—

Turn signal (right) lamp

L11

E/G water temperature (sensor)

—

1st speed indication

—

T/M oil temperature (sensor)

—

2nd speed indication

—

Hour meter (–)

—

3rd speed indication

—

Hour meter (+)

—

Instrument panel illumination

L10

4th speed indication

—

Parking brake lamp

L15

—

65ZV-2 US 62-47 62 Function & Structure Electrical Group Instrument Panel and Switch (S/N 5401~)

1 19

CN2

E S

Pin No.

E S

CN1 12

CN1(24P)

CN2(36P)

12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19

CN1-Signal Secondary steering

80Z562010

Lamp No.

Pin No.

CN2-Signal

Lamp No.

Pin No.

CN2-Signal

Lamp No.

Reversal fan (option)

—

Preheat lamp Declutch lamp

F/R switch (option) —

—

Fuel gauge

T/C (T/M) oil temperature gauge

—

Charge lamp

—

Air cleaner clogging alarm

T/C (T/M) oil temperature alarm

4th speed indication

3rd speed indication

2nd speed indication

1st speed indication

Neutral indication

Engine water temperature alarm

GND (–)

—

Turn signal (left) lamp

Engine oil pressure alarm

AUTO lamp

—

— Central alarm lamp

Backup battery

—

+24 V power supply

—

Tachometer

Instrument panel illumination

—

Parking brake lamp

High-beam lamp

—

— Brake alarm

— 11

—

Work lamp

E/G stop lamp

—

Turn signal (right) lamp

E/G warning lamp

—

Hour meter

—

Engine water temperature gauge

— Controller failure alarm

—

65ZV-2 US 62-48 62 Function & Structure Electrical Group Instrument Panel and Switch

Gauge circuit

Sensors respectively detect the temperature and fuel level, and then, convert them into electric signals. The signals are transmitted to the corresponding gauges that indicate the transmitted values.

(S/N 5001~5400)

Controller

Grounding

Power supply 24V

S E

Note If a gauge is removed from the panel, the resistance between the terminals will differ from the standard value shown in the table.

15V

Viewed from rear surface of instrument panel K90ZV62016

Gauge

Engine water temperature 97ºC(206ºF) 35ºC(95ºF)

T/C, T/M oil temperature 110ºC(230ºF)

100ºC(212ºF) 103ºC(217ºF)

Fuel level

100ºC(212ºF)

120ºC(248ºF)

50ºC(122ºF)

125ºC(257ºF)

Indication

White

Red

White

Resistance between S and E ()

120~125

75~80

115~120

Resistance between S and V ()

120~125

85~90

115~120

Resistance between E and V ()

170~190

130~150

165~170

Engine water temperature

T/C, T/M oil temperature

Fuel level

(S/N 5401~) Gauge

67C° (152.6°F) 50C° (122°F)

125C° (257°F)

56C° 102C° (132.8°F) (215.6°F)

White

Indication

White Red

White

Red

Resistance between S and E ()

80~95

130~150

Resistance between S and V ()

26~30

Resistance between E and V ()

106~126

160~180

65ZV-2 US 62-49 62 Function & Structure Electrical Group Instrument Panel and Switch Temperature sensor (For hydraulic oil temperature and torque converter oil temperature)

115V2E62023

Temperature of detection part (ºC)

80 [176ºF]

90 [194ºF]

100 [212ºF]

120 [248ºF]

Resistance (k)

6.2~6.9

4.7~5.2

3.6~3.9

2.1~2.4

65ZV-2 US 62-50 62 Function & Structure Electrical Group Instrument Panel and Switch

Fuel level sensor

1.4 (0.055 in)

0.197 in) 5 (1.220 31

0.197 in) 67 (2.638 in)

Terminal

Terminal (ground)

FULL

3/4

Resistance wire

1/2

294

5 (11.575 0.197 in) 225.6 (8.882 in) 150 5 (5.906

3 (0.12 in)

(S/N 5001~5106)

1/4

Contact

Float arm Float

Float arm

EMPTY

65ZV62023

65ZV-2 US 62-51 62 Function & Structure Electrical Group Instrument Panel and Switch

(S/N 5107~) Unit terminal

Ground terminal

5 mm (1.220 0.197 in) 31

Body

150

5 mm (11.575 0.197 in)

5 mm (5.906 0.197 in)

Float

1/2

294

Contact Float

Float arm Float

K65V2U62003

The sending unit float arm in the fuel tank moves by the fuel level movement in the tank. The contact installed on the float arm axis also moves by contacting the resistance wire. The contact position is fixed, based on the float position and the fuel level. When the fuel level becomes low, the resistance value rises accordingly. The position of the fuel gauge pointer is decided by this resistance value, and the fuel gauge shows the fuel amount left in the tank.

Fuel gauge

F13 5A Sending unit

Float position Sending unit circuit 65V2E62021

Resistance ()

FULL

3/4

1/2

1/4

EMPTY

(S/N (10 +1.0 - 0.5 ) ~5106)

(19)

32±3

(49.5)

+12 80 +2

(S/N 5107~)

(10 0-4 )

32±5

+12 80 +2

65ZV-2 US 62-52 62 Function & Structure Electrical Group Instrument Panel and Switch

Note Figures in ( ) are for the reference resistance.

65ZV-2 US 62-53 62 Function & Structure Electrical Group MODM

MODM Monitor Changeover

(Machine Operation Diagnostic Module)

[ ]button

Display window

[

]button

[ (step back)] [ (step forward)] button button

Replacement monitor

Fault log monitor

Information monitor

Input/Output monitor

Specification setting monitor

Parameter setting monitor

90ZV-262001

MODM function The MODM has the following functions:

Change over the monitor using the following procedure: When the starter switch is ON, the MODM software version displays for 3 seconds.

- Information monitor Displays outside air temperature, machine speed and engine speed, engine coolant temperature, transmission oil temperature, hydraulic oil temperature and miles driven etc.

80V2U62001

After this, machine information screen displays information relative to the machine function.

- Replacement monitor Allows check of the replacement time for the parts and oil periodically replaced, allows setting of the replacement interval, and displays the replacement pop-ups. - Fault log monitor Allows check of previous errors, and displays active errors. - Input/Output monitor - Parameter setting monitor Allows check and change of the parameter setting. - Specification setting monitor Allows check and change of the specification setting.

80V2U62002

65ZV-2 US 62-54 62 Function & Structure Electrical Group MODM

Changing display from one function to next Press both the [ (step back)] button and [ (step forward)] button at the same time to change over the monitor mode in sequence "Information monitor  Replacement monitor  Fault log monitor  Input/Output monitor  Parameter setting monitor  Specification setting monitor Information monitor".

From Information monitor to Replacement monitor: Press both the [ (step back)] and [ ward)] buttons at the same time. Display should now appear as shown below.

However the monitor mode can not be changed in reverse such as "Information monitor  Specification setting monitor  Parameter setting monitor ....." The display will not be changed to the next monitor when you hold the buttons. For the display sequence, refer to "Outline of MODM (Machine Operation Diagnostic Module) Operation" page 92-59.

(step for-

90ZV-262034

By pressing the [ (step forward)] button or [ (step back)] button you may then continue to navigate through the items that should be replaced at given service intervals.

From Replacement monitor to Fault log monitor: Press both the [ (step back)] and [ ward)] buttons at the same time.

(step for-

70V2U62016

Display should appear as shown. (Example: Downshift button malfunction) This screen shows fault logs or inactive fault codes and provides a chronological date and time line of when they occurred. By pressing the [ (step forward)] button or [ (step back)] button you may then continue to navigate through inactive codes. Up to 100 are stored. In the upper left corner you will notice a numerical sequence of number between 01~00. This represents faults 1~100 as they have been logged.

65ZV-2 US 62-55 62 Function & Structure Electrical Group MODM

From Fault log monitor to Input/Output monitor:

From Specification setting monitor to Information monitor:

Press both the [ (step back)] and [ ward)] buttons at the same time.

(step for-

80V2U62004

With the shift lever in "Neutral" and "Automatic", the screen should appear as above. This screen shows the "Input and Output" signal data.

From Input/Output monitor to Parameter setting monitor: Press both the [ (step back)] and [ ward)] buttons at the same time.

(step for-

80V2U62005

Display should appear similar to above. This screen shows "Parameter settings" and may be used to make changes in an already validated parameter.

From Parameter setting monitor to Specification setting monitor: Press both the [ (step back)] and [ ward)] buttons at the same time.

(step for-

70V2U62017

Display should appear similar to above. This screen shows "Specification settings" and may be used to make changes in a MODM to validate or invalidate a given parameter; effectively turning ON or OFF the function of an option.

(step for-

80V2U62002

While in default temperature screen, the password input screen can be seen by simultaneously pressing the [ ] and [ ] buttons. When the password input is finished, fuel consumption can be seen. Pressing [ ] button toggles between metric and US values.

65ZV-2 US 62-56 62 Function & Structure Electrical Group MODM

Information Monitor

1. Outside air temperature

(Refer to page 92-61)

Information monitor display 90ZV-262024

The following items are displayed: When the starter switch is ON, the software version displays for 3 seconds, then shows default screen.

The monitor displays the current outside air temperature when the starter switch is ON. Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

90ZV-262024

2. Machine speed and engine speed To toggle between metric standard values (ºC, MPa, km/h, etc.) and US standards (ºF, PSI, MPH, etc.), press the [ ] button.

Press the [

(step forward)] button and release.

To get fuel consumption data, press the [ ] and [ ] buttons simultaneously and release, as seen below.

90ZV-262025

You will now be at the screen shown above. 90ZV-262023

When the password input is finished, you will now be at the screen shown below.

This indicates the actual machine speed and engine revolutions. This is useful for determining items like shift mapping patterns in relationship to speed range selection. For speed to be accurate, the correct tire size must be entered into the main MCU via this MODM unit.

80V2U62007

To leave this screen, press the [ ] and [ ] buttons simultaneously again. Every time the [ (step forward)] button is pressed, the displayed contents are changed "Machine speed and engine speed  Engine coolant temperature  Transmission oil temperature  Hydraulic oil temperature" in sequence. Every time the [ (step back)] button is pressed, the displayed contents are changed over in sequence "Hour meter  Voltage  Boom cylinder oil pressure  Cycle". For the display sequence, refer to "Outline of MODM (Machine Operation Diagnostic Module) Operation" page 92-59 and 92-61.

Press the [ ] button to change the display unit from "km/h" to "mph" Press the [ ] button again to return the display unit from "mph" to "km/h".

65ZV-2 US 62-57 62 Function & Structure Electrical Group MODM

3. Current engine coolant temperature and maximum engine coolant temperature recorded (which can be reset)

4. Current transmission oil temperature and maximum transmission oil temperature recorded (which can be reset)

Press the [

(step forward)] button and release.

90ZV-262026

90ZV-262027

You will now be at the screen shown above.

The monitor displays the current engine coolant temperature in the "EG COOLANT" line and maximum engine coolant temperature for the day in the "MAX" line. This self resets daily at 24:00 (12:00 Midnight).

The monitor displays the current transmission oil temperature in the "TC OIL" line and maximum transmission oil temperature for the day in the "MAX" line. This self resets daily at 24:00 (12:00 Midnight).

Even if the engine is stopped once and then started again, if the time is before 24:00, the monitor displays the maximum engine coolant temperature recorded on the day.

Even if the engine is stopped once and then started again, if the time is before 24:00, the monitor displays the maximum transmission oil temperature recorded on the day.

The maximum engine coolant temperature is automatically reset everyday at 24:00, whether the engine starter switch is turned on or off.

The maximum transmission oil temperature is automatically reset everyday at 24:00, whether the engine starter switch is turned on or off.

Immediately after reset, the engine coolant temperature at the time of reset is displayed as the maximum engine coolant temperature. In other words, the current engine coolant temperature is equivalent to the maximum engine coolant temperature.

Immediately after reset, the transmission oil temperature at the time of reset is displayed as the maximum transmission oil temperature. In other words, the current transmission oil temperature is equivalent to the maximum transmission oil temperature.

To manually reset, press the [ ] button to reset the maximum engine coolant temperature. Immediately after reset, the engine coolant temperature at the time of reset is displayed as the maximum engine coolant temperature.

To manually reset, press the [ ] button to reset the maximum transmission oil temperature. Immediately after reset, the transmission oil temperature at the time of reset is displayed as the maximum transmission oil temperature.

Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

65ZV-2 US 62-58 62 Function & Structure Electrical Group MODM

5. Current hydraulic oil temperature and maximum hydraulic oil temperature recorded (which can be reset)

6. Odometer (total miles driven) and trip meter (which can be reset) Press the [

Press the [

(step forward)] button and release.

90ZV-262029 90ZV-262028

You will now be at the screen shown above. You will now be at the screen shown above. The monitor displays the current hydraulic oil temperature in the "HYD OIL" line and maximum hydraulic oil temperature for the day in the "MAX" line. This self resets daily at 24:00 (12:00 Midnight). Even if the engine is stopped once and then started again, if the time is before 24:00, the monitor displays the maximum hydraulic oil temperature recorded on the day. The maximum hydraulic oil temperature is automatically reset everyday at 24:00, whether the engine starter switch is turned on or off. Immediately after reset, the hydraulic oil temperature at the time of reset is displayed as the maximum hydraulic oil temperature. In other words, the current hydraulic oil temperature is equivalent to the maximum hydraulic oil temperature. To manually reset, press the [ ] button to reset the maximum hydraulic oil temperature. Immediately after reset, the hydraulic oil temperature at the time of reset is displayed as the maximum hydraulic oil temperature. Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

The monitor displays the total number of miles that machine is operated in top line and miles for operator selected time frame the trip meter in lower line. This logs miles in forward and reverse. Press the [ ] button to reset the trip meter displayed in lower line. Press the [ ] button to change over the display unit from "km" to "mile". Press the [ ] button again to return the display unit from "mile" to "km".

7. Number of cycles and cycle time Press the [

(step forward)] button and release.

90ZV-262030

You will now be at the screen shown above. The monitor displays the number of cycles in the upper line and the time required for one cycle (moving forward and backward twice) in the lower line. This can be used to determine comparative production data between operators and between working sites. Press the [ ] button to reset both the number of cycles and the cycle time. After reset, the monitor displays newly the number of cycles in the upper line and the time required for one cycle in the lower line.

65ZV-2 US 62-59 62 Function & Structure Electrical Group MODM

8. Hydraulic system oil pressure

Unit conversion and language selection

Press the [

Select the unit and language using the [ ] button.

(step forward)] button and release.

Unit conversion (for traveling distance, temperature and pressure) 80V2U62008

Press the [ ] button once to change the display unit. Press the [ ] button again to return to the previous display unit.

You will now be at the screen shown above. The monitor displays the unloader pressure of the efficient loading system (ELS). Press the [ ] button to change over the display unit from "MPa" to "psi". Press the [ ] button again to return the display unit from "psi" to "MPa".

Language selection Press and hold the [ ] button for 3 seconds or longer to get language selection screen.

9. Voltage Press the [

80V2U62009

(step forward)] button and release. You will now be at the screen shown above. English is selected as the initial setting. 90ZV-262032

You will now be at the screen shown above.

Japanese, French, German, Italian, Spanish, Turkish, Dutch and English can also be selected.

Shows complete electrical system voltage as is seen at the battery level.

Press the [ (step forward)] button or [ back)] button to view the language selections.

Note If voltage drops below 27 V DC, the hibernate mode (lowers RPM’s to conserve fuel) will not work.

For returning to the information monitor after selecting the desired language, press and hold the [ ] button for 2 seconds or longer.

10. Hour meter (total operating hours) and trip meter (which can be reset) Press the [

(step forward)] button and release.

90ZV-262033

You will now be at the screen shown above. The monitor displays total operating hours in upper line, and trip meter hours in lower line. Press the [ ] button to reset the trip meter displayed in the lower line.

(step

For returning to the information monitor without selecting another language, press the [ ] button. Refer to "Main Menu" page 92-60.

65ZV-2 US 62-60 62 Function & Structure Electrical Group MODM

Replacement Monitor

2. Fuel filter

(Refer to page 92-62)

Press the [

(step forward)] button and release.

Replacement time check 1. Engine oil filter

80V2U62010

Press both the [ (step forward)] and [ (step back)] buttons simultaneously to change over the screen from the information monitor to the replacement monitor.

90ZV-262034

You will now be at the screen shown above.

You will now be at the screen shown above. The display window displays remaining time until next replacement of fuel filter cartridge. Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the filter is. Ex. "!12 h" indicates that it is 12 hours overdue.

The display window first displays the remaining time until next replacement of the engine oil filter cartridge. This interval is based on using low sulfur fuel and when engine oil sulfur content is less than 0.5%. If engine oil sulfur content exceeds 0.5%, this interval must be cut in half. Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the filter is. Ex. "!12 h" indicates that it is 12 hours overdue.

80V2U62079

Note Make sure to set the replacement interval (timer reset) whenever the engine oil filter is replaced.

70V2U62018

Note Make sure to set the replacement interval (timer reset) whenever the fuel filter is replaced. It may be necessary to change this filter more frequently, depending on fuel cleanness.

65ZV-2 US 62-61 62 Function & Structure Electrical Group MODM

3. Coolant filter (80ZV-2 ~ 135ZV-2 only)

4. Torque converter and transmission filter

Press the [

(step forward)] button and release.

80V2U62011

80V2U62012

You will now be at the screen shown above.

The display window displays remaining time until next replacement of the engine coolant filter cartridge.

The display window displays remaining time until next replacement of the torque converter and transmission filter cartridge.

Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the filter is.

Ex. "!12 h" indicates that it is 12 hours overdue. Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62019 70V2U62020

Note Make sure to set the replacement interval (timer reset) whenever the coolant filter is replaced. It may be necessary to change this filter more frequently, depending on engine coolant condition.

Note Make sure to set the replacement interval (timer reset) whenever the torque converter and transmission filter is replaced. It may be necessary to change this filter more frequently, depending on transmission oil cleanness.

65ZV-2 US 62-62 62 Function & Structure Electrical Group MODM

5. Hydraulic return filter

6. Engine oil

Press the [

(step forward)] button and release.

80V2U62013

80V2U62014

You will now be at the screen shown above.

The display window displays remaining time until next replacement of hydraulic return filter.

The display window displays remaining time until next replacement of engine oil.

Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the hydraulic return filter change is.

Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the oil change is.

Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62021

Note Make sure to set the replacement interval (timer reset) whenever the hydraulic return filter is replaced.

70V2U62022

Note Make sure to set the replacement interval (timer reset) whenever engine oil is replaced. It may be necessary to change this oil more frequently, depending on work site conditions, oil sampling results and oil cleanness.

65ZV-2 US 62-63 62 Function & Structure Electrical Group MODM

7. Torque converter and transmission oil

8. Axle oil

Press the [

(step forward)] button and release.

80V2U62015

80V2U62016

You will now be at the screen shown above.

The display window displays remaining time until next replacement of torque converter and transmission oil.

The display window displays remaining time until next replacement of both front and rear axle and planetary unit oils.

Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the oil change is.

Ex. "!12 h" indicates that it is 12 hours overdue. Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62023 70V2U62024

Note Make sure to set the replacement interval (timer reset) whenever torque converter and transmission oil is replaced.

Note Make sure to set the replacement interval (timer reset) whenever axle oil is replaced.

It may be necessary to change this oil more frequently, depending on work site conditions, oil sampling results and oil cleanness.

65ZV-2 US 62-64 62 Function & Structure Electrical Group MODM

9. Hydraulic oil

Replacement interval set (timer reset)

Press the [

When the machine is shipped, the standard replacement interval is set as the initial setting.

(step forward)] button and release.

80V2U62017

You will now be at the screen shown above. The display window displays remaining time until next replacement of hydraulic oil. Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the oil change is. Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62025

Note Make sure to set the replacement interval (timer reset) whenever hydraulic oil is replaced. It may be necessary to change this oil more frequently, depending on work site conditions, oil sampling results and oil cleanness.

Press and hold the [ ] button for 2 seconds or more on the replacement monitor screen to display the timer reset screen. The timer reset screen displays the standard replacement interval. For setting the standard replacement interval, press the [ ] button. Then, the standard replacement interval is set, and it returns to the replacement monitor screen again.

65ZV-2 US 62-65 62 Function & Structure Electrical Group MODM

Replacement interval pop-up

Example: Engine oil

90ZV-262037

When the remaining time until the next replacement interval reaches " 0 " (or 0 hours), the replacement popup appears and flashes in the display window.

For setting the replacement interval other than the standard replacement interval, follow the procedure below: 90ZV-262038

 50  100 (2 seconds or more)  50  100 (2 seconds or more) Press the [ (step forward)] button once to add "50" hours. Press the [ (step forward)] button twice to add "100" hours. Press the [ (step forward)] button three times to add "150" hours. "50" hours is added every time the [ (step forward)] button is pressed. Every time the [ (step back)] button is pressed, "50" hours is subtracted. When the [ (step forward)] button is pressed and held for 2 seconds or more, "100" hours is added continuously. It means that "100", "200", "300" hours ..... is added in 100 hour increments. 90ZV-262039

When the [ (step back)] button is pressed and held for 2 seconds or more, "100" hours is subtracted continuously in the same manner. After setting the replacement interval, press and hold the [ ] button for 2 seconds or more. The replacement interval is reset, and the display returns to the replacement monitor screen again.

When two or more replacement pop-ups occur at the same time, the corresponding items flash in turn. After the remaining time for the next replacement reaches " 0 ", the corresponding pop-up appears up to three times when the starter switch is ON. (The MODM software version is displayed for 3 seconds, and then the replacement pop-up flashes.) When the [ (step forward)] button, [ (step back)] button, [ ] button or [ ] button is pressed, it returns to the previous screen again. After replacing the corresponding filter or oil, return to the timer reset screen and set the replacement interval. Refer to the replacement interval set (timer reset) procedure above.

65ZV-2 US 62-66 62 Function & Structure Electrical Group MODM

Display language The same language selected in the information monitor is used as the display language for the replacement monitor. For selecting the display language, it is necessary to return to the information monitor. The display language can be selected only on the information monitor screen.

Fault Log Monitor (Refer to page 92-63) Start from key ON. Press the [ (step back)] button and [ (step forward)] button together twice to get to this point.

Fault log history check 1. Active faults

For returning from the replacement monitor to the information monitor, change the monitor in turn as described in the sequence "Replacement monitor [ ][ ] (pressing them at the same time)  Fault log monitor [ ][ ] (pressing them at the same time)  Input/ Output monitor [ ][ ] (pressing them at the same time)  Parameter setting monitor [ ][ ] (pressing them at the same time)  Specification setting monitor [ ][ ] (pressing them at the same time)  Information monitor". For the display sequence, refer to "Outline of MODM (Machine Operation Diagnostic Module) Operation" page 92-59.

Up to 100 machine faults and 100 engine faults can be recorded in fault log (200 total). Failure codes that begin with CN are machine faults. (CN=Chassis fault #) Failure codes that begin with EN are engine faults. (EN=Engine fault #) What is shown The following list of items are shown. Fault descriptor, fault code number, date of occurrence and hour-minutesecond of occurrence. Examples shown below. This shows fault CN321. This is caused by an engine coolant temperature fault (open circuit). Note descriptions.

Fault descriptor

Date July 20, 2006

Fault code

Time in 24:00 hour scale 3:27:32 PM 80V2U62018

This shows fault EG117. This is caused by an engine coolant temperature sensor fault.

65V2E62022

Fault codes are split into input and output signals.

65ZV-2 US 62-67 62 Function & Structure Electrical Group MODM

2. Inactive faults (Checking history )

Selection of machine fault log and engine fault log

Again, up to 100 machine faults and 100 engine faults can be recorded in the fault log (200 faults total). Failure codes that begin with CN are machine faults.

You can toggle between viewing the engine faults or machine faults.

Failure codes that begin with EN are engine faults.

Machine fault

What is shown The following list of items are shown. Order of occurrences, fault code number, date, hour-minute-second, and quantity of occurrence. Examples shown below.

When the machine fault log screen is displayed, press and hold the [ (step forward)] button for 2 seconds or more to display the engine fault log screen which shows the latest engine fault code.

This shows fault CN321. This is caused by an engine coolant temperature fault (open circuit). Note descriptions.

Order of occurrences 100 total 01~00 Fault code number

A=Active fault 002 is qty of occurrences

80V2U62022

Engine fault When the engine fault log screen is displayed, press and hold the [ (step back)] button for 2 seconds or more to display the machine fault log screen which shows the latest machine fault code.

Date July 20, 2006

Time in 24:00 hour scale 3:27:32

65V2E62019 80V2U62020

This shows fault EG117. This is caused by an engine coolant temperature sensor fault. Note descriptions.

Order of occurrences 100 total 01~00 Fault code number

Date July 25, 2006

A=Active fault 016 is qty of occurrences

Time in 24:00 hour scale 1:31:38 65V2E62023

..... If still active, shows "A" before fault number.

The machine fault log screen and engine fault log screen can be distinguished as follows: Displayed fault code: CN ..... Machine fault log screen EG ..... Engine fault log screen

65ZV-2 US 62-68 62 Function & Structure Electrical Group MODM

Machine fault log navigation When two or more fault codes are recorded, press the [ (step forward)] button to display the next latest fault code. Press the [ (step back)] button to display the fault code in chronological order.

Engine fault log navigation When two or more fault codes are recorded, press the [ (step forward)] button to display the next latest fault code. Press the [ (step back)] button to display the fault code in chronological order.

Clear fault log Clear inactive fault log Fault codes can be cleared by pressing the [ ] button and holding it for more than 2 seconds while in the engine fault mode, or in the machine fault mode screens. Note When pressing the [ ] button to clear a fault code, password entry is required on the 65ZV-2 S/N 5123 and thereafter. The password must be acquired from the Kawasaki Service Representative and is not for general public use as it can cause troubles if the necessary troubleshooting information is deleted. If you have the password, write it in the value entry blanks provided below. ____ DO NOT GIVE THIS PASSWORD OUT TO CUSTOMERS OR END USERS!

Press and hold the [ ] button for 2 seconds or more to clear the entire fault log. When there are two or more fault codes recorded, all fault codes recorded are cleared by performing the clear fault log operation once. Press the [ ] button not to clear the fault log and to return to the machine fault log screen again. Note To clear engine fault codes, you must be in the engine fault screen. To clear machine fault codes, you must be in the machine fault screen. Individual faults cannot be cleared only one at a time. All engine or machine faults are cleared at once. Note any fault codes prior to erasing them from memory, in case you need that information later. After engine fault codes (EGXXX) or machine fault codes (CNXXX) have been cleared, the buzzer will sound to alert that the code has been erased from memory. If you do not hear the buzzer, the fault codes have not been erased from memory history.

65ZV-2 US 62-69 62 Function & Structure Electrical Group MODM

Clear active fault log (error pop up) (S/N 5001~5014 only) When a fault occurs, the corresponding fault code is forcibly displayed on the screen. When two or more active faults occur, up to 5 fault codes each are displayed repeatedly. (Up to total 10 fault codes for CN and EG errors together) For deleting the displayed fault codes, press one of the [ (step forward)] button, [ (step back)] button, [ ] button or [ ] button.

80V2U62024

Then, the screen displayed before the active fault codes appears again. Active fault codes are displayed repeatedly when the starter switch is ON and will continue to display until the cause of each fault code is eliminated. If there is a fault that has been erased, and the cause is not repaired, the fault will quickly reappear in the screen due to being active. It will continue to reappear until the underlying cause of the fault is eliminated.

65ZV-2 US 62-70 62 Function & Structure Electrical Group MODM

Failure code (Input side) Code

Failure

Detection condition (In case of)

CN121

Shift lever F & R switch malfunction

Shift lever F & R contact ON at the same time Failure continues for more than 3 seconds

CN122

Shift lever 1•2•3•A switch malfunction (1)

Shift lever any of more than two 1•2•3•A contact ON at the same time Failure continues for more than 3 seconds (30 seconds from program ver. 100915).

CN123

Shift lever 1•2•3•A switch malfunction (2)

All 1•2•3•A signal OFF continues for more than 3 seconds (30 seconds from program ver. 100915).

CN141

Shift-up switch malfunction

Switch is ON for more than 10 seconds

CN142

Shift-down switch malfunction

Switch is ON for more than 10 seconds

CN143

Shift-up switch & shift-down switch malfunction

Shift-up switch & shift-down switch contact ON at the same time Failure continues for more than 3 seconds

CN145

Kick-down switch malfunction

Switch is ON for more than 10 seconds

CN146

Shift hold switch malfunction

Switch is ON for more than 10 seconds

CN151

T/M oil pressure switch malfunction (This applies to the model 115ZV-2/135ZV-2 only)

Signal OFF continues for more than 10 seconds during engine running

CN152

T/M oil pressure sensor malfunction (This applies to the model 95ZV-2 only)

T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more than 10 seconds during engine running

CN161

Machine speed sensor malfunction (1)

Input circuit is disconnected for more than 3 seconds

CN162

Machine speed sensor malfunction (2)

Input value is over 70 km/h (44 mile/h) for more than 3 seconds

CN163

E/G speed sensor 1 (ECM output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is OFF (Input circuit is disconnected)

CN164

E/G speed sensor 1 (ECM output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is OFF

CN165

E/G speed sensor 2 (Sensor output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is ON (Input circuit is disconnected)

CN167

E/G speed sensor 2 (Sensor output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is ON

CN213

Inching sensor malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN214

Inching sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN232

S/S potentiometer malfunction (1)

Voltage is lower than 0.1 V for more than 3 seconds

CN234

S/S potentiometer malfunction (2)

Voltage is larger than 4.9 V for more than 3 seconds

CN236

S/S shift switch (F & R contact) malfunction

Failure continues for more than 3 seconds

CN251

Secondary steering oil pressure sensor malfunction(1)

Voltage is lower than 0.2 V for more than 3 seconds

CN252

Secondary steering oil pressure sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN254

Low secondary steering oil pressure

Oil pressure sensor detects secondary steering oil pressure below 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine running

CN262

Kickout potentiometer malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN263

Kickout potentiometer malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN271

Efficient loading system hydraulic oil pressure senVoltage is lower than 0.2 V for more than 3 seconds sor malfunction (1)

CN272

Efficient loading system hydraulic oil pressure senVoltage is larger than 4.6 V for more than 3 seconds sor malfunction (2)

CN312

Brake oil pressure sensor 1 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN313

Brake oil pressure sensor 1 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN315

Brake oil pressure sensor 2 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN316

Brake oil pressure sensor 2 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN321

E/G coolant temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN323

E/G coolant temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN341

T/M oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN342

T/M oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

65ZV-2 US 62-71 62 Function & Structure Electrical Group MODM

Code

Failure

Detection condition (In case of)

CN351

Hydraulic oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN352

Hydraulic oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN381

Fuel level sensor malfunction

Input signal corresponds to "any other pattern" in fuel level indication table

CN391

Air temperature probe malfunction (1)

Input voltage is larger than 4.35 V for more than 3 seconds

CN392

Air temperature probe malfunction (2)

Input voltage is lower than 0.13 V for more than 3 seconds

CN412

Abnormal brake oil pressure (1)

Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/ cm2) (592 psi) for more than 1 second during engine running

CN413

Abnormal brake oil pressure (2)

Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6 kgf/cm2) (592 psi) more than 1 second during engine running

CN414

Abnormal brake oil pressure difference

Brake oil pressure difference switch is in abnormal condition for more than 1 second

CN415

Abnormal brake oil amount

Brake oil amount switch is in abnormal condition for more than 1 second

CN421

Abnormal engine oil pressure

Engine oil pressure switch is OFF for more than 2 seconds during engine running

CN431

Abnormal engine coolant temperature (1)

Engine coolant temperature switch is ON for more than 2 seconds

CN432

Abnormal engine coolant temperature (2)

Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition for more than 2 seconds

CN451

Abnormal T/M oil temperature (1)

T/M oil temperature switch is ON for more than 2 seconds

CN452

Abnormal T/M oil temperature (2)

T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more than 2 seconds

CN461

Abnormal hydraulic oil temperature

Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for more than 2 seconds

CN471

Clogged T/M oil filter

30 minutes after starter switch is ON, T/M oil filter switch is ON for more than 2 seconds when T/M oil temperature sensor detects oil temperature more than 60 deg. C (140 deg. F)

CN481

Clogged air cleaner element

Air cleaner switch is ON for more than 2 seconds

Abnormal cooling water level in radiator

Radiator cooling water level switch is OFF for more than 2 seconds when the engine is off.

CN496

Abnormal hydraulic oil level

Hydraulic oil level switch is in abnormal condition for more than 30 seconds

CN497

Abnormal brake disc oil temperature (This applies to the model 135ZV-2 only)

Brake disc oil temperature switch is ON for more than 1 second

CN498

Abnormal disc wear (This applies to the model 135ZV-2 only)

Brake disc wear switch is ON for more than 1 second

CN801

CAN disconnect

CAN line is disconnected

CN802

Abnormal engine coolant temperature (CAN)

No engine coolant temperature data received for more than 3 seconds

CN912

Abnormal MCU voltage (1)

Voltage is larger than 32±1 V

CN913

Abnormal MCU voltage (2)

Voltage is lower than 22±0.5 V for more than 10 seconds during engine running

CN491

(CN_In 14F05)

Fuel level display table Input

Output

1/8

1/4

1/2

3/4

1/4

1/2

3/4

—

Other than above

—

: No input signal given

: Lamp on

x : Input signal given

—

— : Lamp off

—

— —

: Lamp flashing

—

Note This table applies to the 95/115/135ZV-2 units.

65ZV-2 US 62-72 62 Function & Structure Electrical Group MODM

Failure code (Output side) Code

Failure

Detection condition

CN512

F solenoid valve malfunction

F solenoid valve is short-circuited or disconnected

CN514

R solenoid valve malfunction

R solenoid valve is short-circuited or disconnected

CN516

1st solenoid valve malfunction

1st solenoid valve is short-circuited or disconnected

CN518

2nd solenoid valve malfunction

2nd solenoid valve is short-circuited or disconnected

CN521

3rd solenoid valve malfunction

3rd solenoid valve is short-circuited or disconnected

CN524

4th solenoid valve malfunction

4th solenoid valve is short-circuited or disconnected

CN526

D solenoid valve malfunction

D solenoid valve is short-circuited or disconnected

CN528

H solenoid valve malfunction

H solenoid valve is short-circuited or disconnected

CN531

LU solenoid valve malfunction

LU solenoid valve is short-circuited or disconnected

CN534

Auto-brake solenoid valve malfunction

Auto-brake solenoid valve is short-circuited or disconnected

CN536

Speed change control solenoid valve malfunction (1)

Speed change control solenoid valve is short-circuited

CN537

Speed change control solenoid valve malfunction (2)

Speed change control solenoid valve is disconnected

CN621

S/S solenoid valve R malfunction (1)

S/S solenoid valve R is short-circuited

CN622

S/S solenoid valve R malfunction (2)

S/S solenoid valve R is disconnected

CN623

S/S solenoid valve L malfunction (1)

S/S solenoid valve L is short-circuited

CN624

S/S solenoid valve L malfunction (2)

S/S solenoid valve L is disconnected

CN631

Pressure increase solenoid valve malfunction

Pressure increase solenoid valve is short-circuited or disconnected

CN641

Ride control solenoid valve malfunction

Ride control solenoid valve is short-circuited or disconnected

CN681

Efficient loading system selection solenoid valve malfunction

Efficient loading system selection solenoid valve is short-circuited or disconnected

CN712

Cooling fan solenoid valve malfunction (1)

Cooling fan solenoid valve is short-circuited

CN713

Cooling fan solenoid valve malfunction (2)

Cooling fan solenoid valve is disconnected

CN721

Hour meter drive malfunction

Hour meter drive is short-circuited

(CN_Out 10F24)

Failure code (Engine) Refer to "Diagnosis trouble code (DTC) information" page 62-19.

65ZV-2 US 62-73 62 Function & Structure Electrical Group MODM

Input/Output Monitor

By pressing the [ (step forward)] button, you will arrive at a window as shown below.

(Refer to page 92-64)

Input/Output monitor display 80V2U62026

1. Input signal monitor From a position of turning on the key switch, press both the [ (step back)] and [ (step forward)] buttons simultaneously 3 times, you will arrive at the screen shown below.

80V2U62025

This is because in window 2, it shows the parking brake as being released and the corresponding slot would have a 1 in that place. In other words, the parking brake coil has been energized and the slot has a 1 in it indicating that it is energized and the parking brake is released. Now press the [ (step forward)] button once. You will arrive at the screen shown below.

This is the beginning of the section for input and output signal display. 80V2U62027

Input signal monitor (D1~D7) This monitor displays the ON/OFF status of the shift lever, setting switches, pressure switches, etc. There are seven input groups from INPUT 1 to INPUT 7.

Nothing in this case is activated, so all of the slots are occupied with the number 0. Now press the [ (step forward)] button once. You will arrive at the screen shown below.

Each group has eight items from item 0 to 7. When input signal is ON, "1" is displayed under corresponding item number.

80V2U62028

When input signal is OFF, "0" is displayed under corresponding item number.

The screen indicates that ride control and ELS are activated, or the switch for each one is energized.

Refer to "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" page 92-68.

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

As shown in table of section "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" that follows, the selection below reflects that forward and automatic have been selected by the shift lever.

80V2U62029

This indicates that the engine is running as the place for alternate neutral voltage under slot 3 is occupied by a 1. 80V2U62025

65ZV-2 US 62-74 62 Function & Structure Electrical Group MODM Now press the [ (step forward)] button once. You will arrive at the screen shown below.

2. Current output monitor Every time the [ (step forward)] button is pressed and held for 2 seconds, the displayed contents are changed. First item seen is as shown below.

80V2U62030

This indicates that there are no inputs happening in this situation.

Note The [ (step back)] or [ (step forward)] button must be held for 2 seconds or more with each change. If not, it will not move to next item.

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

If the feature is set to "Invalid" in specification setting, the following items will be skipped. - STEERING PRESS - SP7 (EMG steering)

80V2U62031

- BOOM ANGLE - SP15 (Lift kickout)

This indicates that there are inputs for a full fuel tank, the machine is equipped with an optional reversing fan, and the switch for the fan is in the "ON" or energized position. Now press the [ (step forward)] button once. You will arrive back the screen shown below.

90ZV-262019

This area is called the "Current Output Monitor". As seen, it first shows actual front brake circuit pressure. Next, by pressing the [ (step forward)] button, the following screen is seen if equipped with secondary steering.

80V2U62025

You have completely reviewed all of the input signals. 80V2U62032

Again, in review, note the following: - This monitor displays the ON/OFF status of the shift lever, setting switches, pressure switches, etc.

Next, by pressing the [ following screen is seen.

(step forward)] button, the

- There are seven input groups from INPUT 1 to INPUT 7. 80V2U62033

- Each group has eight items from item 0 to the item 7. - When input signal is ON, "1" is displayed under corresponding item number.

Next, by pressing the [ following screen is seen.

(step forward)] button, the

- When input signal is OFF, "0" is displayed under corresponding item number. 80V2U62034

For more clarification, refer to "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table".

65ZV-2 US 62-75 62 Function & Structure Electrical Group MODM Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62035

Note Brake main pressure 1 is accumulator oil pressure for rear accumulator which serves only the rear brake circuit. Brake main pressure 2 is accumulator oil pressure for front accumulator which serves the front brake circuit and all pilot derived pressures; these are pilot oil pressure for the pilot control valves, auto brake, park brake release, etc. The actual real-time pressures are shown in these fields. Next, by pressing the [ following screen is seen.

(step forward)] button, the

3. Output signal monitor (D1~D6) This monitor displays the ON/OFF status of the transmission forward/backward solenoid valves, speed range solenoid valves, indicator lamps and warning lamps on the instrument panel, etc. There are six output groups from OUTPUT 1 to OUTPUT 6. Each group has eight items from item 0 to 7. When output signal is ON, "1" is displayed under corresponding item number. When output signal is OFF, "0" is displayed under corresponding item number. Refer to "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" page 92-68. Next, by pressing the [ (step forward)] button for 2 seconds or longer will show the following screen.

90ZV-262019

You have now navigated through the entire "Current Output Monitor" part of the "Input and Output Monitor" section. All of the aforementioned screens can be seen in reverse order by using the [ (step back)] button. Holding this button in for longer than 2 seconds will take you to the input signal monitor screen section.

80V2U62036

This shows the 2nd speed solenoid coil and the forward coil outputs have been applied, as the transmission is in forward and automatic. 1st, 3rd, 4th, reverse, high, and auto brake solenoid coils are not energized and show no application signal. Next press the [ following screen.

(step forward)] button to show the

80V2U62037

Again, note that all values except the last are 0, and only the brake lamp output is in the "ON" position.

65ZV-2 US 62-76 62 Function & Structure Electrical Group MODM Next press the [ following screen.

(step forward)] button to show the

4. Electric current output monitor This indicates the milliampere (mA) of electric current that are being sent to the fan solenoid valve from the MCU.

80V2U62038

Press the [ (step forward)] button for 2 seconds or longer to show the following screen.

All values are at 0 as there are no outputs needed in this scenario. Next press the [ following screen.

(step forward)] button to show the 80V2U62042

80V2U62039

This current output will vary as demands for fan revolutions change, according to amount of heat that is being generated. This heat must be discharged to cool the system that is heating back down.

Note that the place under slot 5 is occupied by a 1, as MCU failure relay should be energized by MCU if MCU passes software logic test at MCU boot-up that occurs with the key in the "ON" position.

When the machine systems are cold and the machine is in warm up mode, the mA level will be higher than when the machine has worked for a time and has become heat saturated.

Next press the [ following screen.

Note Disconnecting the fan solenoid wire will increase the fan’s revolutions to full speed, and will set a CN713 fault code. This will reside in the system fault code memory until it is cleared. If you disconnect the solenoid coil, you must remember to clear this fault code when finished with work.

(step forward)] button to show the

80V2U62040

Note that the place under slot 1 is occupied by a 1, as the unit is in automatic shift mode and the dash lamp should be illuminated to indicate this. Also the place under slot 7 is occupied by a 1, as the unit is full of fuel. Next press the [ following screen.

(step forward)] button to show the

80V2U62041

Note that this shows no input signal at this time.

Refer to fault code table for the chassis side for more detail.

65ZV-2 US 62-77 62 Function & Structure Electrical Group MODM

Parameter Setting Monitor

1. Shift inhibitor

(Refer to page 92-65)

From turning on key switch which would default to screen shown below.

Parameter setting monitor display This monitor allows check of parameters that are currently set.

80V2U62002

Value levels to set parameter for items like ride control, tire ratios, date/time clock (used to log faults), declutch pressures, secondary steering, detent values sensor, etc. Note If the feature is set to "Invalid" in specification setting view, the following items will be skipped in the parameter setting monitor view. - RIDE CONTROL - SP5 (Ride control) - EMG STEERING - SP7 (EMG steering) - K-LEVER - SP8 (K-Lever) - TRACTION CONTROL - SP11 (Traction control)

Pressing both the [ (step forward)] and [ (step back)] buttons simultaneously, 4 times once after another, arrive at the screen shown below.

80V2U62005

The transmission changes the speed range automatically according to the machine speed. If the machine speed sensor is disconnected when the machine is running high, the machine speed is suddenly reduced because of that the transmission is automatically shifted to the low range. As a result, the operator becomes very unstable condition by rapid deceleration. This device prevents the above.

- 2 STAGE - SP13 (Efficient loading system) - BOOM SOFT LAND - SP14 (Lower kickout)

By pressing the [ (step forward)] button, you will arrive at a window as shown below.

- KICK OUT - SP15 (Lift kickout) 80V2U62043

65ZV-2 US 62-78 62 Function & Structure Electrical Group MODM

2. Ride control

Press the [ (step forward)] button to add "1" to a numerical value.

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

80V2U62044

Note Value for "ON" must be 1 km/hr or more greater than "OFF". The numerical value will increase as you press the [ (step forward)] button as follows;

The screen should appear similar to what is shown. This shows the speed at which ride control turns on and permits the base end oil to work against the accumulator piston.

0  1  2 ..... 9  0  1  2 .....

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

The number then decreases as follows;

80V2U62045

The screen should appear similar to what is shown. This shows the speed at which ride control turns off and does not permit the base end oil to work against the accumulator piston. Changing ride control on/off speed values: These values can be changed for machines that are equipped with this option by doing the following. Press and hold the [ ] button for 2 seconds or more on the parameter setting screen to display the parameter change screen. The cursor flashes in a 1-second cycle (flashes on for 0.5 second and flashes off for 0.5 second). Press the [ ] button to move the cursor. The cursor moves to the right. When the cursor reaches the right end in the upper line, pressing [ ] button will move it to the left end in the lower line. When the cursor reaches the right end in the line, pressing [ ] button moves it to the left end in the line. The cursor skips digits which can not be changed. Cursor movement: Moving to the right  Right end in the upper line  Left end in the lower line  Right end in the lower line  Left end in the upper line.

Press the [ (step back)] button to subtract "1" from a numerical value.

9  8  7 ..... 0  9  8  7 ..... After changing parameter values, press and hold the [ ] button for 2 second or more to finalize the input values and return to the parameter setting screen. Press the [ ] button to return to the parameter setting screen without changing parameter values.

65ZV-2 US 62-79 62 Function & Structure Electrical Group MODM

3. Meter division ratio Next, by pressing the [ following screen is seen.

4. Tachograph (step forward)] button, the

Next, by pressing the [ following screen is seen.

80V2U62046

The screen should appear similar to what is shown. This is the speed division ratio for the smaller tire. This permits the speed reading to be accurate when equipped with smaller tires. Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62048

Next, by pressing the [ following screen is seen.

(step forward)] button, the

(step forward)] button, the 80V2U62049

5. Secondary steering 80V2U62047

Next, by pressing the [ following screen is seen.

The screen should appear similar to what is shown. This is the speed division ratio for the larger tire. This permits the speed reading to be accurate when equipped with larger tires. Note Model

(step forward)] button, the

80V2U62050

The screen should appear similar to what is shown and indicates the engagement speed.

Tire size Small size (B)

Large size (A)

65ZV-2

17.5

20.5

70ZV-2

20.5

23.5

80ZV-2

20.5

23.5

85ZV-2

23.5

26.5

90ZV-2

23.5

26.5

92ZV-2

26.5

95ZV-2

26.5

29.5

115ZV-2

29.5

35/65

When this option is on the machine, this screen will permit the technician to see the engagement speeds. This will engage when the machine loses power to the engine, or if the steering pump were to fail and hydraulic system pressure falls below 0.4 MPa (4 kgf/cm2) (57 psi) as long as the machine speed is above 2 km/h, and it disengages when the speed falls below 1 km/h. Next, by pressing the [ following screen is seen.

(step forward)] button, the

Note that the 1/12 ratio is the small size (B), and the 1/ 11 ratio is the large size (A). 80V2U62051

65ZV-2 US 62-80 62 Function & Structure Electrical Group MODM

6. K-Lever (stick steering) (80ZV-2 ~ 115ZV-2) Next, by pressing the [ following screen is seen.

(step forward)] button, the

Review the following screens that are able to be seen by pressing the [ (step forward)] button. (A setting shown.)

80V2U62055 80V2U62052

The screen should appear similar to what is shown and indicates the K-Lever voltage.

80V2U62056

Note The default setting for K-Lever is to the "A" type. The voltage settings are displayed in the MODM monitor display.

80V2U62057

i=Signal intensity (or mA) Review the following screens that are able to be seen by pressing the [ (step forward)] button. (A setting shown.)

A Type

Solenoid valve LH side

Solenoid valve RH side

Current (mA)

imax i2

80V2U62053

80V2U62054

V=Voltage The screen should appear similar to what is shown and indicates the K-Lever mA signal strength or intensity.

Potentiometer (V)

V1 V2 Vmax

2.5 V1

5 V2 Vmax

Note The default setting for K-Lever is to the "A" type. The voltage settings are displayed in the MODM monitor display.

80V2U62077

Initial set values K-LEVER V1

0.25 V

K-LEVER V2

2.0 V

K-LEVER Vmax

2.4 V

K-LEVER i1

290 mA

K-LEVER i2

450 mA

K-LEVER imax

470 mA

65ZV-2 US 62-81 62 Function & Structure Electrical Group MODM

7. Traction control (95ZV-2 ~ 115ZV-2)

B Type

Solenoid valve LH side

Next, by pressing the [ following screen is seen.

Solenoid valve RH side

Current (mA)

imax

(step forward)] button, the

i2 80V2U62058

i1 Potentiometer (V)

V1 V2 V3

2.5 V1

5 V2

This indicates parameter of 1.0 second when in forward and 1st (F1) gear before traction control will engage. If time of engagement for F1 is less than 1 second, it is looked at as not permanent; software will not respond to signal as it is considered to be inconsequential. This helps avoid erratic machine function.

Vmax

Vmax 80V2U62078

Next, by pressing the [ following screen is seen.

(step forward)] button, the

Initial set values K-LEVER V1

0.25 V

K-LEVER V2

1.0 V

K-LEVER V3

2.0 V

K-LEVER i1

290 mA

K-LEVER i2

400 mA

K-LEVER i3

450 mA

K-LEVER imax

470 mA

Note Type A and B are switched on the specification setting monitor. (Refer to page 62-87)

80V2U62059

This stands for Dual Stage for slip control. This parameter is not used in USA production and should be disregarded. (It would have set a given hydraulic system pressure value to indicate that machine was excavating and MCU logic for traction control would take into account this additional parameter.) Next, by pressing the [ following screen is seen.

(step forward)] button, the

In case of type A, screen changes as follows. 80V2U62060

V1  V2  Vmax  i1  i2  imax In case of type B, screen changes as follows. V1  V2  V3  i1  i2  i3  imax

This stands for Inching slip control feature and is not used. This parameter is not used in USA production and should be disregarded. (If it were used, declutch (or inching circuit) sensor would signal MCU to know brake circuit pressure & deactivate traction control if the brake circuit pressure was over a given value for a given time frame (See "ti" below; ti is also not used).)

65ZV-2 US 62-82 62 Function & Structure Electrical Group MODM Next, by pressing the [ following screen is seen.

(step forward)] button, the

Next, by pressing the [ following screen is seen.

80V2U62061

This is time inching. This is time frame in lsc above. Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62065

This stands for Slip Control time; data is provided in seconds of time. When the set time for starting slippage begins, traction control engages and makes adjustments accordingly.

8. Declutch 80V2U62062

Next, by pressing the [ following screen is seen.

(step forward)] button, the

This stands for Slip Control velocity, or ground speed regulation for traction control "ON"; speed has to be at or below this setting to activate traction control. 80V2U62066

Next, by pressing the [ following screen is seen.

(step forward)] button, the This is brake circuit pressure; at this pressure, the declutch circuit will put the transmission to neutral position, and delete the forward or reverse clutch output. IS stands for Inching Sensor. 80V2U62063

This stands for Slip Control engine, or engine speed regulation for traction control "ON"; rpm speed has to be at or above this setting to activate traction control. Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62064

This stands for Slip Control intensity; indicates accelerated slipping velocity of traction control. The value is indicated in km/h per 0.1 second. Each 1/10th of a second the velocity is cut back by engine rpm reduction so slippage will not occur, and this provides reduced tire slippage.

65ZV-2 US 62-83 62 Function & Structure Electrical Group MODM

9. Efficient loading system (ELS)

10. Engine power control (70ZV-2 ~ 115ZV-2)

Next, by pressing the [ following screen is seen.

Temperature

(step forward)] button, the

Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62067

This is the voltage at the rotary sensor wire that returns signal to MCU. This signal from the rotary sensor determines the boom height position. If the boom is high, the unloader valve solenoid coil at the ELS control valve will not be energized, and the ELS will not operate to unload the loading pump.

80V2U62070

The screen should appear similar to what is shown. This is the temperature at which hibernate mode will engage.

DS=Dual Stage (or ELS)

TWni=Temperature Water normal idle.

on="on". (Thus the term "DSon".)

Voltage

This indicates that the dual stage system is on when it senses 2.5 V or less.

Next, by pressing the [ following screen is seen.

(step forward)] button, the

Typical voltage for the rotary sensor is as shown in graphic below (approximate values). 65V2E62024

Approximate voltage values Boom fully up=4.8 V

The screen should appear similar to what is shown. This is the voltage at which hibernate mode is changed to normal operation mode forcibly. Vni=Voltage normal idle. If the voltage is less than 26.7 V DC, hibernate low idle will not engage. This is so battery will stay charged.

80V2U62068

Bucket can be in any orientation

Boom fully down=0.40 V Carry level

80V2U62069

65ZV-2 US 62-84 62 Function & Structure Electrical Group MODM

11. Lower kickout (for return to dig)

13. Calendar (Date and time)

Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62072

The screen should appear similar to what is shown; voltage will vary. When lowering, position can be set to make the detent system stop bucket prior to hitting the ground. The MCU will recognize this only when value is 2.50 V or less. If it is greater than 2.50 V, MCU ignores the signal.

12. Lift kickout (for boom raise) Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62073

The screen should appear similar to what is shown; voltage will vary. Ks=Kickout set point When raising boom, position can be set to make the detent system stop the boom prior to the piston hitting the cylinder head. The MCU will recognize this only when value is 4.20 V or more. If it is less than 4.20 V, MCU ignores the signal. This feature protects boom cylinders from inertial damage caused by the mass of the boom, bucket, and linkage moving up rapidly with the boom cylinders extending and causing the pistons to hit the boom cylinder heads.

(step forward)] button, the

90ZV-262022

The screen should appear similar to what is shown.

65ZV-2 US 62-85 62 Function & Structure Electrical Group MODM

Parameter change The parameter values can be changed when the both conditions below are satisfied: The engine is stopped (starter switch is ON). The parking switch is ON.

Press the [ (step forward)] button to add "1" to a numerical value. The numerical value will increase as you press the [ (step forward)] button as follows. 0  1  2 ..... 9  0 Press the [ (step back)] button to subtract "1" from a numerical value. The number decreases as follows.

A parameter value can be changed, however, only when the corresponding item is set to "VALID" in the specification setting monitor. (Refer to page 92-65) Ride control setting 1

9  8  7..... 0  9 After changing parameter values, press and hold the [ ] button for 2 second or more to finalize the input values and return to the parameter setting screen. Press the [ ] button to return to the parameter setting screen without changing parameter values.

When the corresponding item is set to "INVALID", the parameter screen is not displayed. (It is skipped to the next screen.) Calendar

The date & time sequence reads as shown. DATE TIME

YY / MM / DD hh : mm : ss

Y=year M=month D=day 90ZV-262022

Changing date and clock values:

h=hour m=minute s=second

These values can be changed by doing the following.

Example:

Press and hold the [ ] button for 2 seconds or more on the parameter setting screen to display the parameter change screen.

DATE TIME

The cursor flashes in a 1-second cycle (flashes on for 0.5 second). Press the [ ] button to move the cursor. The cursor moves to the right. When the cursor reaches the right end in the upper line, pressing [ ] button will move it to the left end in the lower line. When the cursor reaches the right end in the lower line, pressing [ ] button will move it to the left end in the upper line. The cursor skips digits which cannot be changed. Cursor movement: Moving to the right  Right end in the upper line  Left end in the lower line  Right end in the lower line  Left end in the upper line

06 / 07 / 12 = July 12, 2006 20 : 15 : 11 = 8:15:11 pm

Note Failure to enter the values correctly will make the clock give the wrong time, and the date to read incorrectly in all of the dependent functions, such as fault code messages, etc.

65ZV-2 US 62-86 62 Function & Structure Electrical Group MODM

Specification Setting Monitor

1. Specification setting display

(Refer to page 92-66 and 92-67)

This monitor allows check of the specifications currently set.

Specification setting monitor display From turning on key switch which would default to screen shown below.

When attaching an optional unit, change the specification setting to make the corresponding function valid. It is necessary to log with the correct password for changing the specification setting.

80V2U62002

Pressing both the [ (step forward)] and [ (step back)] buttons simultaneously, 5 times once after another, arrive at the screen shown below.

If no password is entered, only the initial specification setting monitor can be seen, and is shown the program number that is designed for that particular machine model.

80V2U62074

When you are at this point, press the [ (step forward)] button for over 2 seconds will take you to the following screen.

90ZV-262023

The asterisk symbol will have a flashing _ underscore below it, indicating that it is ready to have a password entered into it to permit login access to change variable parameters. The login access code must be acquired from the Kawasaki Service Representative and is not for general public use as it can cause machine troubles if the wrong parameters are inserted. If you have the password, write it in the place value entry blanks provided below. _ _ _ _ DO NOT GIVE THIS PASSWORD OUT TO CUSTOMERS OR END USERS ! IT IS FOR TRAINED KAWASAKI SERVICE PERSONNEL ONLY ! SERIOUS DAMAGE TO MACHINE MAY RESULT BY USING INAPPROPRIATE ENTRY VALUES.

65ZV-2 US 62-87 62 Function & Structure Electrical Group MODM

2. Password entry and changing settings Note To make changes to entry settings, engine must be "OFF", and key switch in "ON" position with parking brake applied. Otherwise changes will not happen.

90ZV-262023

Every time the [ (step back)] button is pressed, the displayed content is changed "FR switch  Wheel type  Kickout  ..." in sequence. The following items can now be selected as "VALID" or "INVALID" by pressing and holding the [ ] button for 2 seconds or longer, and then selecting the [ (step forward)] or the [ (step back)] button to choose "VALID" or "INVALID" as required. When finished, press and hold the [ ] button for 2 seconds or longer to accept the change.

The password is a numerical password. Press the [ (step forward)] button to add "1" to a numerical value.

If you need to return without making a selection, press the [ ] button, and you will return to the previous screen without making a change of selection.

The numerical value will increase as you press the [ (step forward)] button as follows;

- Selection switch shift (shift lever or F/R switch) Valid/Invalid

0  1  2  3  4  5 ..... 9  0  1  2  3  4  5 ..... etc.

- Shift hold Valid/Invalid

Press the [ ] button to change the cursor position to continue password entry. When finished, press the [ ] button for longer than 2 seconds to get to the following screen.

- Ride control Valid/Invalid - Secondary steering Valid/Invalid - K-Lever (Stick steering) A Type/B Type/Invalid

80V2U62075

Every time the [ (step forward)] button is pressed and held for 2 seconds, the displayed contents are changed over "All setting reset  Specification group 1  Specification group 2  All setting reset" in sequence. Every time the [ (step back)] button is pressed and held for 2 seconds, the displayed contents are changed over "All setting reset  Specification group 2  Specification group 1  All setting reset" in sequence. For the display sequence, refer to "Outline of MODM (Machine Operation Diagnostic Module) Operation" page 92-59. Specification group 1 Every time the [ (step forward)] button is pressed, the displayed content is changed "FR switch  Shift hold  Ride control  ..." in sequence.

- Hydraulic pressure increase Valid/Invalid - Traction control Valid/Invalid - Tachograph Valid/Invalid - Efficient loading system (ELS) Valid/Invalid - Lower kickout Valid/Invalid - Lift kickout (variable) Valid/Invalid - Wheel type A type (Big wheel)/B type (Small wheel)

65ZV-2 US 62-88 62 Function & Structure Electrical Group MODM Specification group 2 Every time the [ (step forward)] button is pressed, the displayed content is changed "Downshift button  Auto brake  Engine speed  ..." in sequence. Every time the [ (step back)] button is pressed, the displayed content is changed "Downshift button  Brake oil level  Brake oil differential sw  ..." in sequence.

- Engine oil pressure sensor (for communication and monitor control) Valid/Invalid - Brake pressure differential switch Valid/Invalid - Brake oil level Valid/Invalid Use the table on page 62-91 to do this.

The following items can now be selected as "VALID" or "INVALID" by pressing and holding the [ ] button for 2 seconds or longer, and then selecting the [ (step forward)] or the [ (step back)] button to choose "VALID" or "INVALID" as required. When finished, press and hold the [ ] button for 2 seconds or longer to accept the change. If you need to return without making a selection, press the [ ] button, and you will return to the previous screen without making a change of selection. - Kick-down (downshift button) Valid/Invalid - Auto brake Valid/Invalid - Engine speed Communication/Sensor - E/G curve selection Communication/Output/Invalid - Cooling fan Valid/A type/B type - Transmission oil temperature switch (for monitor control) Valid/Invalid - Engine coolant temperature switch (for monitor control) Valid/Invalid - Engine coolant temperature sensor (for monitor control) Net/Sensor - Engine oil pressure switch (for monitor control) Valid/Invalid

You may exit back to the default screen when finished by pressing the [ (step forward)] and [ (step back)] buttons simultaneously.

WARNING Changing the systems parameters to non factory settings will render the monitor ineffective. This can lead to warranty claims that will not be covered by the factory warranty. DO NOT VALIDATE OPTIONS OR SETTINGS THAT DO NOT APPLY !

65ZV-2 US 62-89 62 Function & Structure Electrical Group MODM

All setting reset Item

Allows batch deletion or batch reset of information monitor, replacement monitor or fault log monitor. Specified Parameter

Comment

Kick down (downshift button)

SP1

Always valid

Selection switch shift (shift lever or F/R switch)

SP2

Optional

Information monitor When this is performed, the following items will be reset.

Shift hold

SP3

Always invalid

Auto brake

SP4

Valid 92~135ZV-2

Ride control

SP5

Option

Engine speed

SP6

Sensor

Secondary steering

SP7

Option (EU always valid)

- Maximum hydraulic oil temperature

K-Lever

SP8

Option

- Number of cycles

Engine curve

SP9

Output

Hydraulic pressure increase (power up)

SP10

Option

- Cycle time - Trip meter (for hour meter)

Traction control

SP11

Valid 92~135ZV-2

Tachograph

SP12

Always invalid

Efficient loading system (ELS) SP13

Option on 65/70ZV-2

Lower kickout

Always valid

SP14

- Maximum engine coolant temperature - Maximum transmission oil temperature

Replacement monitor

Lift kickout

SP15

Always valid

Cooling fan

SP16

A type

Torque converter oil temperature switch

SP17

Invalid

- Fuel filter timer

Engine coolant temperature switch

SP18

Invalid

- Coolant filter timer

Engine coolant temperature sensor

SP19

Net or Sensor

- Torque converter line filter timer

- Engine oil filter timer

Engine oil pressure switch

SP20

Always valid

Engine oil pressure sensor

SP21

Sensor (INVALID)

- Hydraulic oil return filter timer

Brake pressure differential switch

SP22

50/60ZV-2 only

- Engine oil timer

Brake oil level

SP23

50/60ZV-2 only

Wheel type

SP24

A or B type

- Torque converter and transmission oil timer - Axle gear oil timer - Hydraulic oil timer After timers are reset, each of them is automatically set to the standard initial set value.

Fault log monitor - The machine fault log is deleted. - The engine fault log is deleted. Note This can be reset with engine running. It will retain reset results.

65ZV-2 US 62-90 62 Function & Structure Electrical Group MODM

All setting reset procedure (Start at screen shown)

80V2U62075

Press and hold the [ ] button for 2 seconds or more to display the all setting reset execution screen. See example below.

80V2U62076

When executing the all setting reset function, press and hold the [ ] button for 2 seconds or more. Then, the all setting reset function is executed, and the specification setting screen appears again. Press the [ ] button to return to the specification setting screen without executing the all setting reset function.

65ZV-2 US 62-91 62 Function & Structure Electrical Group MODM

Default position of specification setting monitor ITEM

OPTION EITHER VALID OR INVALID

65ZV-2 65TMV-2

70ZV-2 70TMV-2

80ZV-2

85ZV-2

90ZV-2

92ZV-2

95ZV-2

115ZV-2

Kick down (downshift button)

Valid/Invalid

Selection switch shift (shift lever or F/R switch)

Valid/Invalid

Shift hold

Valid/Invalid

x 



Auto brake

Valid/Invalid

Ride control

Valid/Invalid

Engine speed

Net/Sensor

Sensor

Secondary steering

Valid/Invalid

K-Lever

Valid/Invalid

Engine curve

Output/Net/Invalid

Hydraulic pressure increase (power up)

x

Output

Valid/Invalid

Traction control

Valid/Invalid

Tachograph

Valid/Invalid

Efficient loading system (ELS)

Valid/Invalid

Lower kickout

Valid/Invalid

Lift kickout

Valid/Invalid

Cooling fan

A type/B type/Invalid

A type

Torque converter oil temperature switch

Valid/Invalid

Engine coolant temperature switch

Valid/Invalid

Engine coolant temperature sensor

Sensor/Net***

Net

Sensor/ Net

Net

Sensor/ Net

Engine oil pressure switch

Valid/Invalid

Engine oil pressure sensor

Valid/Invalid

Brake pressure differential switch

Invalid/Nc/No

Brake oil level

Invalid/Nc/No

Wheel type

A or B type

A type

=Valid x=Invalid  Auto brake is always valid on 95/115ZV-2 units.

 Pilot operated hydraulics for K-Lever on 115/135ZV-2.

Items that are not shaded in table are addable options.

Note*** Concerning engine coolant temperature sensor, “Net” must be selected for the listed S/N machines in the following table, and “Sensor” must be selected for the machines prior to them. (The sensor wes no longer installed but temperature data was derived from the engine ECM on and after the listed S/N.)

Model

Serial number to use “Net”

65TMV-2/65ZV-2

Always “Net” (all S/N)

70TMV-2

70C5-4051~

70ZV-2

70C5-5251~

80ZV-2

80C5-5251~

85ZV-2

85C5-5101~

90ZV-2

90C5-5151~

92ZV-2

Always “Net” (all S/N)

95ZV-2

97C5-5251~

115ZV-2

11C5-5101~

65ZV-2 US 62-92 62 Function & Structure Electrical Group Electrical Detent Circuit

Electrical Detent Circuit Bucket leveler After dumping, if the control lever is set to the "rollback" position, the control lever will be held at that position until the bucket is tilted to the set angle. This is because the detent solenoid in the pilot valve is energized so that the fixing disc connected to the push rod is held by the magnetic force. When the bucket is positioned at the set angle, the rod will retract from the proximity switch. The proximity switch is turned off and the detent solenoid in the pilot valve is de-energized and demagnetized. The control lever is automatically returned to the neutral position by the spring. As a result, the bucket is set to the selected digging angle automatically.

Detent (Pilot valve)

Control valve

Adjusting rod (detected object)

Proximity switch

Connector Bucket cylinder

65V2U62001

65ZV-2 US 62-93 62 Function & Structure Electrical Group Electrical Detent Circuit

Proximity switch Adjusting the clearance

Proximity switch Switch main circuit

LED

+24V

Br 1

Coil for detent inside pilot valve

B 2 L 3 +24V

Detection part Operation indicator lamp (LED) Detected object

1(Br)

View Z 3(L)

5±2 mm (0.197±0.079 in)

Adjust the clearance between the sensor and the adjusting plate to 5±2 mm (0.197±0.079 in). In this condition, the operation indicator lamp (LED) is on, and the circuit between the switches (2) – (3) is on.

2(B) 85ZV62015

65ZV-2 US 62-94 62 Function & Structure Electrical Group Electrical Detent Circuit

Detent solenoid

Push rod

Solenoid

Plate

65V2U62002

Three detent solenoids are installed in the pilot valve. One detent solenoid, for the bucket leveler, is installed in the pilot valve bucket side. Two detent solenoids, for the boom kickout and float, are installed in the pilot valve boom side. Voltage

DC 24 V

Coil resistance

120 

65ZV-2 US 62-95 62 Function & Structure Electrical Group Electrical Detent Circuit

Lift kickout & lower kickout Location

4 A

1 Detail A

65V2E62011

1. Rotary sensor assy 2. Rod 3. Link 4. Cover 5. Boom

Lift kickout When the boom control lever is placed at "Raise" position and the boom reaches at the preset height, the lift kickout automatically releases the detent and returns the boom control lever to "Hold" position. The detent function and the units are the same way as those of the bucket leveler.

Lower kickout When the boom control lever is placed at "Float" position and the boom reaches at the preset height, the lower kickout automatically releases the detent and returns the boom control lever to "Hold" position. The detent function and the units are the same way as those of the bucket leveler.

65ZV-2 US 62-96 62 Function & Structure Electrical Group Electrical Detent Circuit

Sensor assy 4

3 3

5 A-A

Detail of grease applying

A 30 Position sensor detail

85V2E62009

1. Position sensor 2. Link 3. Plate 4. Shaft 5. Ball bearing

65ZV-2 US 62-97 62 Function & Structure Electrical Group Electrical Detent Circuit

A B C

View A

A Position sensor detail

CCW

70T2U62008

70T2U62009

Resistance

5 k ± 1 k

Electrical rotation

128º (Theoretical)

Mechanical rotation

180º

Clockwise stop

90º from elect. center

Spring return

To clockwise end of rotation

65ZV-2 US 62-98 62 Function & Structure Electrical Group Electrical Detent Circuit

Detent solenoid

[For lower kickout]

Preset height adjustment

[For lift kickout]

Push rod

Switch Solenoid

Solenoid

Plate

Plate (Upper)

65V2U62005a

(Lower)

Hold

Reset

65V2U62003 65V2E62018

Two detent solenoids are installed in the pilot valve boom side. One is for the lift kickout and another is for the lower kickout. Voltage

DC 24 V

Coil resistance

120 

1. Lift kickout preset height Raise the boom to the desired position and press the left side of the kickout control switch located on the console box to set the boom height for the lift kickout. 2. Lower kickout preset height Lower the boom to the desired position and press the right side of the kickout control switch located on the console box to set the boom height for the lower kickout.

65ZV-2 US 62-99 62 Function & Structure Electrical Group Diode

Diode Open circuit, failed in open position

Symbols

+24V Switch

Solenoid

[Anode]

[Cathode]

Surge voltage

(forward direction)

Current flow

(backward direction)

70ZV62051

Diode

Current flows while the diode is disconnected. (The solenoid is energized, however the surge voltage is not absorbed. This damages electrical parts.) 70T2U62011

A diode is an electronic part which makes the current flow in one direction.

Normal Current flow

+24V

The + side is called "anode", and the - side is called "cathode". The current can flow only in the direction from the anode to the cathode.

Switch

When a diode is connected in the current flow direction, it is called forward direction. When a diode is connected in the current non-flow direction, it is called backward direction.

Solenoid

Diode

Current flows while the diode is normal (The solenoid is energized.)

70ZV62052

Short-circuit, failed in closed position.

Some electrical parts, as solenoid valves, buzzers, relays, all equipped with electromagnetic coils may generate a surge voltage caused by counter electromotive force when the power is turned off. This surge voltage may cause malfunction of equipment. Diodes are provided to prevent such a malfunction.

+24V

Switch Solenoid

Diode

Current flows through the diode with smaller resistance. The solenoid is not energized. 95ZV62074

However, if a diode is damaged and short-circuited (or fails closed) in its inside, electronic parts may be harmed. Therefore, if a malfunction occurs in electrical equipment, electrical connection diagrams should be referred to first, to determine and repair the cause. If a diode is provided in the electrical equipment, the diode should be checked for damage.

65ZV-2 US 62-100 62 Function & Structure Electrical Group Diode

Diode check method

Caution for diode check method Continuity check mode When checking the continuity by continuity check mode of volt-ohm-ammeter, only in case that the resistance is about 300  or smaller, the continuity is detected.

Coil

If the continuity check mode of volt-ohm-ammeter is used to check the continuity of diode with 500~600 , no continuity is detected both ways.

+ Analog type tester

Use a volt-ohm-ammeter with diode mode for checking diode continuity. 95ZV62129

12V

Diode check mode

12V

30A

Battery (1)

ECM F15

R1 BR B AC R2 C

(2) (3)

15A

(2)(3): Diode unit

F13

F14

10A

Suppression diode Charge circuit

From alternator L terminal

Neutral relay 65V2E62017

Normal

Abnormal

Forward check

Continuity is detected in the status shown in the figure. Continuity is not detected when tester terminals are connected in opposite way. Continuity is not detected in either way Disconnection Continuity is detected in either way

Short-circuit

Note When the circuit tester is the digital (number indication) type, exchange the positions of the terminals of the tester during the check. Some solenoid coils contain diodes inside the solenoid coil pack. Backward check 85V2E62036

Forward check

Backward check

Judgement

Continuity (voltage value)

Over level

Normal

Over level

Open circuit

0 volt

Short-circuit

65ZV-2 US 62-101 62 Function & Structure Electrical Group Diode

Resistance check mode Analog type tester

R1>0

R2=

Forward check

Backward check Digital type tester

R1>0

R2=

Forward check

Backward check

Forward check

Backward check

R  (0<R<)



Judgement Normal



Open circuit

0

Short-circuit

65ZV-2 US 62-102 62 Function & Structure Electrical Group Diode

Surge voltage and surge suppression diodes

Fig. 3

Fig. 1

Surge suppression diode

Coil

Current Switch or transistor Time [sec]

Load 115ZVE62032

Some electrical parts such as solenoid valves are equipped with a coil. When a coil is energized, an electromagnetic field is formed. See fig. 1. Fig. 2

Battery

Coil

When the switch opens, the field collapses across the coil windings. Voltage

Voltage [V] Current [A]

K70V2J62006

When the surge voltage was generated, it causes to increase wear on the switch points. During the coil is being activated by the transistor, when the excruciating high voltage is loaded on the transistor, the transistor may be broken. In order to absorb this surge voltage, connect the diode parallel to the coil in the reverse direction against the power supply. When the switch is off, the same amount of electric current, that was flown till now, flows through the diode. This electric current is attenuated gradually and finally it reaches zero. That means no surge voltage is generated in the circuit.

Current

Load

Coil

Voltage

Voltage [V] Current [A]

Current direction

Battery

Electromagnetic field forms when switch closes.

This diode is called as flywheel diode.

ON OFF Time [sec]

Surge voltage 115ZVE62033

When the solenoid coil is de-energized, the field collapses across the coil. The collapse of this electromagnetic field across the solenoid coil generates an unregulated voltage surge. See fig. 2. This can damage transistors, contacts, and other electronic parts. (See connection diagram.)

65ZV-2 US 72-1 72 Function & Structure Operator Station Group

72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050) ............................ 72-2 Air Conditioner (S/N 5051~) .................................... 72-37

65ZV-2 US 72-2 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Air Conditioner (S/N 5001~5050) Air conditioning systems

Air conditioning unit

Very often, things are much simpler than they may appear. This is also the case with an air conditioning system. Gas when compressed often heats as a result of molecular compression, and when decompressed it cools. Some gases are more prone to heat or cool to a greater degree when undergoing these changes than are others. We use these natural laws to make an air conditioning system work.

As an example of manipulating refrigerant temperatures, imagine that you can very quickly make the refrigerant intensely hot. This is done by use of a compressor, as we just mentioned in paragraph one.

Another factor to take into consideration is that we enhance the natural effects of hot and cold in these refrigerants by manipulating the gas temperature while it is undergoing the heating or cooling process. Note HFC 134A is a refrigerant that is a very effective vehicle to carry away heat.

If you course the heated refrigerant that just came from the compressor through a condenser that will cool it while it is very hot and in a compressed gaseous state, you will make it shed some of its heat that it gained in the compression process. This refrigerant then is converted into a liquid at this point, while still in the condenser. This is why it is called the condenser, as it has condensed the gas into a liquid. As a liquid that may still contain some minor gas fractions, it is routed into the receiver drier. There it dries the refrigerant by use of a material we term a “desiccant”, which means drying agent. A down tube in the receiver drier is submerged into the heavier liquid that is now at the bottom of the receiver drier. This tube will permit passage of only the heavier liquid that is at the bottom of the receiver drier. Then the high-pressure liquid passes through the thermal expansion valve that provides a restriction or throttles the flow of refrigerant. This restriction reduces the pressure of the liquid refrigerant thus reducing its boiling point. The expansion valve also meters the amount of refrigerant to the evaporator, by modulating the valve from wide open to closed, which varies with the heat load. The expansion valve separates the high-pressure side from the low-pressure side. The refrigerant is now at the evaporator. Temperatures in the evaporator are cold enough to cause the ambient air to cool when blown through it. This causes condensation to happen. The fan-charged air that rushes through the evaporator is now going to shed its humidity. This humidity, or condensed water, is routed through some tubing to be discharged to the outside of the cabin as waste water that falls to the ground. The refrigerant is now on its way back to the compressor. It is still under pressure when compared to the atmospheric air pressure. However, because it is drawn along by the refrigerant compressor suction, we now say that is in the suction side (low-pressure side) of the circuit.

65ZV-2 US 72-3 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Bergstrom air conditioner structure Fuse unit

Relay

Air conditioner unit

Control box

Air damper (blower)

Control switch panel

K90ZV72004

65ZV-2 US 72-4 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Coil box unit Screws Inside air filter Top cover Inside air filter cover

Insulation material for thermal barrier and sound deadening Evaporator core

Evaporator core freeze detection sensor Seal

Heater core

Thermal expansion valve High pressure switch Seals

Low pressure switch

Outlet

Heater heat control actuator

Inlet

Gaskets

Fresh & recirculation air door

Fan speed relays (3)

Insulation material for thermal barrier and sound deadening

Gasket Drain K95V2U72001

65ZV-2 US 72-5 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Fan box unit Top cover

Louver Screen and gasket unit

Cooler box

Insulation material for thermal barrier and sound deadening

Fan housing

Fan motor

“Squirrel cage” unit

Fan motor bracket Fan housing Fan housing box Fan motor

Screen and gasket unit

“Squirrel cage” unit Fan motor bracket

Pulse width modulators

Insulation material for thermal barrier and sound deadening

K95V2U72002

65ZV-2 US 72-6 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

134A refrigerant compressor

Magnetic clutch wire Clutch wire

Magnetic clutch

Compressor

High pressure side

Low pressure side

Compressor oil fill port 95ZV72001

Designed to compress vapor. Not designed to compress any type of a liquid. Compressor can be damaged by non compressible substances as liquids (especially water), dirt/ contamination, liquid refrigerant, compressor oils, etc. Be careful if you want to add compressor oil, as you can hydro-lock the compressor if you add oil to wrong ports before installation. Sufficient oil is already installed in rotary case end before installation. Verify that there is no need for adding oil at time of startup of new compressor. The replacement compressor will normally be tagged to explain how much, if any, oil is required. The compressor draws vapor from evaporator and compresses it to a high pressure. This pressure varies according to ambient temperature and actual amount of refrigerant in system.

Note Never start compressor if lines are disconnected, or either suction or discharge side, or both are blocked. - Note the low and high pressure service valves that are capped off to keep valves clean. Red cap is high pressure, black cap is low pressure. The high pressure line is smaller than low pressure suction line. Lines are sized differently, and will not interchange. R-134A refrigerant requires Polyalkaline Glycol (PAG) oil, not Mineral based refrigerant oil. Be careful not to mix these oils. Proper belt alignment is important to the life of the belt, bearings, and pulleys.

65ZV-2 US 72-7 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Compressor details

Refrigerant compressor Drive belt

Mount brackets

Engine

K95V2U72003

Note - R-134A refrigerant requires Polyalkaline Glycol (PAG) oil, not Mineral based refrigerant oil. Be careful not to mix these oils. - Proper belt alignment is important to the life of the belt, bearings and pulleys.

Compressor electro-magnetic drive clutch

Electrically activated drive clutch

95ZV72002

Belt driven, electrically actuated clutch. The clutch is a two wire type; one is internally grounded, and other is actuated by a system induced electrical signal. When actuated, the magnetic coil locks the belt driven disk to the compressor shaft disk, and drives the refrigerant compressor assembly to compress the refrigerant vapor. The pulley is mounted on a bearing which is able to rotate freely without turning the compressor when clutch is not engaged.

65ZV-2 US 72-8 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Condenser

Thermostatic expansion valve

95ZV72003

The condenser transfers heat from hot refrigerant to outside air. Condenser fans cause the air to flow across the condenser, thus increasing the transfer of heat from the condenser to outside air. (Drawing above is from the model 95ZV-2. Other models may vary, but are similar in appearance.)

Means by which heat energy changes refrigerant vapor to liquid. The condenser must radiate sufficient heat energy to do this. If obstructed, or not able to transfer heat properly, can cause a buildup of compressor "head pressure" on high side, and pressure sensing switches will disengage the compressor clutch. (Refer to high and low pressure switches later on). Obstructions to efficiency of condenser are. 1. Bad fan motors, blades, or connections between these. 2. Obstructions to air flow. Should be free from airflow obstructions and permit a large volume of heat to escape from system. (Leaves, sticks, dirt, etc. Appropriate tooling may be used to remove debris, as a comb tool, or a 90º bent air blower device to clear debris from fins. If a pressure washer is used, care should be taken not to damage condenser fins.) 3. Bent cooling fins. (A comb tool may be used to maintain fins. If a pressure washer is used, care should be taken not to damage condenser fins.) 4. Unclean surfaces cut effectiveness of condenser.

95ZV72005

Lowers pressure before the refrigerant enters evaporator. Pressure is reduced by passing refrigerant through orifice. Orifice size is variable, and is controlled to compensate for changes in pressure and temperature. Temperature of the refrigerant at the outlet of the evaporator determines orifice size, and is varied by a gas expansion bulb assembly that moves the orifice valve seat by way of a diaphragm and pin arrangement.

65ZV-2 US 72-9 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Receiver / Drier Sight glass

Bubbles visible in the sight glass Receiver drier

Liquid

Normal

Abnormal

Fig bubbles in the sight glass

Kawasaki recommends replacing the receiver drier every 3 years, 6000 hours, or whenever the sight glass changes colors.

Liquid line to evaporator 115ZV72002

Combination refrigerant reserve and "filter" assembly. Stores and filters the refrigerant. Desiccant (as phosphorous pent oxide or calcium oxide) is used to contain minor water fractions that have entered into system. It is capable of absorbing up to 20% (about 2 teaspoons) of its’ weight in water. Equipped with a sight glass. (Bubbles are visible in sight glass on top of drier when charging system.) Some have a moisture indicator in sight glass, which turns to a pink/white color when water is present. Remains blue when no water is present. Dry refrigerant is imperative for efficient system operation. Filter screen stops solid contaminants from leaving unit. Blockage results in change of pressure indicated by a drop in temperature. The unit also prevents gaseous refrigerant from reaching thermostatic expansion valve. When in storage, it MUST be capped off to prevent air entry.

65ZV-2 US 72-10 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Evaporator core and temperature sensor

Evaporator thermal switch

Evaporator core

Heater core

Thermal expansion valve High pressure switch

Low pressure switch

Heater heat control actuator

K95V2U72004

Evaporator Located in cab. Is mounted in low pressure side of air conditioning circuit, immediately after the expansion valve. Absorbs heat from surrounding air, by fan forced air passing over the evaporator (the higher the fan setting, the quicker the heat/cool transfer). The evaporator transfers this heat to the refrigerant. Refrigerant expands rapidly in the evaporator, and refrigerant temperature is increased as cab is cooled.

Exchange of heat from air to refrigerant depends on difference in temperature. With a high heat load, the system must work longer to transfer sufficient heat to cool cab to an acceptable level. After this level is reached, the fan speed can be reduced. This reduction in fan speed makes the system more efficient.

65ZV-2 US 72-11 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Evaporator thermal switch

Senses evaporator temperature and provides signal to engage or disengage the compressor clutch to prevent evaporator freeze up.

Thermal switch

The thermal switch is equipped with a small capillary line that contains ether. This gas expands and contracts according to the temperature of the tube. This switch detects the evaporator core temperature and is normally closed when the evaporator core is in operating condition. When the core gets too cold (-2~0ºC) (28~32ºF) and the temperature in the capillary tube gets close to freezing, the gas contracts and the switch turns to the “off” position.

Heater core

Evaporator core

K95V2U72005

Thermal switch

Evaporator core

Thermal expansion valve

High & low pressure switches

Heater core

Water valve K95V2U72006

When the core gets warmer and the temperature in the capillary tube rises above the freezing level (1~3ºC) (34~38ºF), the gas expands and the switch turns to “on” position, thus alerting the amplifier that the compressor clutch may be engaged again.

65ZV-2 US 72-12 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Pressure switch

High pressure switch location

Low pressure switch

Low pressure switch location

The low pressure switch monitors air conditioner operation. It is mounted on low side of A/C circuit, just after the thermal expansion valve. It engages and disengages the compressor clutch.

The low pressure switch is a naturally open switch, at atmospheric pressure. Remains open until 30 PSI, above which it will remain infinitely closed. If pressure drops below 10 PSI, switch will open and remain open until it reaches 30 PSI again. A system with pressure equalized on both sides will show this switch closed, because it will be above its’ opening pressure. 70ZV72002

High pressure switch The high pressure switch monitors air conditioner operation. It is mounted on high side of A/C circuit; it engages and disengages the compressor clutch. The high pressure switch is naturally closed switch, at atmospheric pressure. It remains closed until pressure reaches 360 PSI, above which remains open. When pressure drops to 230 PSI, the switch closes. This pressure threshold also protects the compressor from high pressure restart lockup. A system with R134A pressure equalized on both sides will show this switch closed, because it will be below its’ opening pressure.

65ZV-2 US 72-13 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Defroster/Operator ventilation and heater valve actuator motors

Duct (RH shown)

Upper vent (FACE)

- This duct assembly has actuators that are mounted directly to it's side. These ducts control the air that flows to the operators face, and the defroster, as well as to the area of the operators feet. - Notice that the duct bolts to the front of the cab at a plate that is designed to mount it in it's place.

To defrost

- The bottom and top have gaskets to seal the air so that it goes where directed. - There are two different actuator part numbers. One operates Clock-wise (CW). The other operates Counter Clockwise (CCW). If the actuator is not used in the proper position the system will not operate properly.

Actuator (CCW)

Lower vent (FEET)

95ZV72010

Actuator and damper door arrangements are located at the floor to dash duct areas as shown in the illustration. The machine operator programs into the controller what he wants the heater and air conditioner to do, such as, defrost or blow air from the floor vents. The controller then sends a signal to the actuators as needed, which open or close ventilation doors that direct the air to the correct destination. Then the window is defrosted, or the operator is cooled, etc. There is also an actuator located at the heater core coil area to open and close the heater valve. This makes a total of five different actuators. Note The actuators run on a 12 volt signal that is received from the controller.

65ZV-2 US 72-14 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Control panel

K90ZV72002

1. Mode control switch 2. Heat/AC control switch 3. Temperature control switch 4. Blower control switch

View A K95V2U72007

65ZV-2 US 72-15 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Plug in interface

Plug part No. DTO4-08PA-E004

95ZV72014

This is where the electrical connects to the machine harness. This is located at the side console, below the fuses, and is accessed at the right side cab door.

65ZV-2 US 72-16 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Electrical pins locations

35829-60120

650650

B 1

BER650713

BER650712

LOW PRESSURE SWITCH C11

HIGH PRESSURE SWITCH C12

PKD 12052644

A B

650650

FREEZE SWITCH C9A C10B

C11 36505-60080 BER868952

36505-60090 BER868951

DUCT ASSEMBLY

DUCT ASSEMBLY 5 6 7 8 9 10

33191-60530

HARNESS +24 VDC

C3 1 2 3 4 5 6 7 8 9 10 11 12

CONTROL

HPD24-24-21PN A B C D E BLWR SPD F G H WV SIG J K L M +24 VDC N P R S T U V W X

+24 VDC

Transistorized GND

CON12

1 2 3 4 5 6 7 8 COND FAN COND FAN A/C FUSED

33191-60520 HDP26-24-21SN 12V A GND B C D PWR1 E BLOWER SPEED F G H WV SIG J A/C REQ K A/C COMP L M EVAP_TEMP N P R S T U V 12V 2 W X

+24 VDC

DT06-2S-EP06

C15

+24 VDC

1 2 3 4 5 6 7 8 9 10 11 12

Ground

+24 VDC

33435-60280

PWM 1

C15 DT06-12SA-EP07

C18 30 85 87A 87 86

Protected +24 VDC

1 2

45050-60080

POWER RELAY 1 PKD 12033871

C14

C14 BER203208 BLOWER MOTOR 2 DT06-2S-EP06

A B

COND_RLY

C17 BER203208 BLOWER MOTOR 1

HARNESS

HD34-24-21PN A B C D E F G H J K L M N P R S T U V W X

A/C_COMP A/C_FUSED

COND_FAN

COND_RLY

PKD 12040953

30 85 87A 87 86

RIGHT BOTTOM ACTUATOR

PKD 12065686

30 85 87A 87 86

PKD 12040953

5 6 7 8 9 10

1 2

33191-60540

HARNESS

HDP26-24-21SN A 12V GND B C +BATT 24V D A/C_COMP E BLOWER SPEED F COND_RLY G H WV SIG J A/C REQ K A/C COMP L M EVAP_TEMP N P R S T U V 12V_2 W X

C1 LEFT BOTTOM ACTUATOR

WATER VALVE PKD 12040953

C17 Protected +24 VDC

+24 VDC

5 6 7 8 9 10

BER868708

To compressor clutch

+24 VDC

+12 VDC

33435-60270 33435-60290

J7 5 6 7 8 9 10

Ground

PKD 12040953 GND

PKD 12040953

C12

VEHICLE HARNESS C8 DT04-08PA-E004

RIGHT TOP ACTUATOR 1

5 6 7 8 9 10

LEFT TOP ACTUATOR

GROUND LUG GND

PKD 15300002

A B

Note See page 92-38 for the larger diagram.

A/C CLUTCH FUSE (See upper left corner)

C16 +24 VDC

+24 VDC

PKD 12085030

LS1 87A 30

Ice Cube Relay detail

87 85 86

87a VF4-15F13

Ground

1 2 3 4 5 6 7 8 9 10 11 12

PWM 2 DT06-12SA-EP07

45050-60070

+24 VDC

C3 (Main System Controller)

C3 connector when looking at the back of controller. It is a 12 pin Deutsch connector.

K95V2U72009

45050-60080

POWER RELAY 2 PKD 12033871

30 85 87A 87 86

Coil

C19 30 85 87A 87 86

45050-60080 PKD 12033871

C20 A/C RELAY

K65T2U72001

Pin connections Note Below do not coincide necessarily with the layout of the address diagram when looking at the machine harness connection.

C16

CONDENSOR RELAY

The diagram to the right is for condenser, A/C & Power 1 & 2 relays.

33435-60280

GND

16 black

12 V

18 red

+BATT IN

18 red

TOP

18 white

BOTTOM

18 white

(UNUSED)

AC_REQ

18 white

WV SIG

18 white

BLWR. SPD

18 white

(UNUSED)

65ZV-2 US 72-17 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050) C15, C16 (PWMC)

Connections as viewed from harness side. This type plug is for the Pulse Width Modulation fan speed controllers (PWMC).

K95V2U72010

C11, C12 (Pressure Switch)

C11

Low pressure switch

C12

High pressure switch

As seen from harness side. K95V2U72011

C14, C17 (Blower Fan Motor)

Fan motor connection as seen from harness side. (2 Pin Deutsch connector) K95V2U72012

65ZV-2 US 72-18 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Panel switches

1. Mode control switch

Manual heater control (Heat only)

Provides the signal to adjust the mode doors to direct the air flow.

Ventilator Upper

Lower

Window (Defrost)

Open

Mode Panel Mode

Bi-Level Mode

4 K95V2U72013

Manual combo control (A/C and Heat)

Floor Mode

Mix Mode

2 Defrost Mode

2. Heat/AC control switch On the Combo control, it enables/disables the AC function. 3

Air conditioner on Air conditioner off

K90ZV72002

3. Temperature control switch Adjusts the output temperature. This output is used to control the position of the water valve. 4. Blower control switch Turn the control fully counter clockwise to turn off the blower, or adjust the blower to the desired speed.

65ZV-2 US 72-19 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Air conditioner troubleshooting

Diagnostic step - Maintenance & operation

WARNING

95ZV72029

WARNING Always act responsibly! - System is under pressure. Wear protective goggles and gloves when working on Air conditioning system. - Abide by local, state, and federal laws.

95ZV72033

IMPORTANT Never plug in electrical components while circuits are energized. This can result in damage to some electrical components, which may lead to premature component failure. Make sure connection behind the controller is good! Before going deep into electrical diagnosis, FIRST inspect system for mechanical problems like trouble with belts, problems with plugged condenser, poor hose and tubing condition, leakage around seals, CONTROLLER LOCKED IN THE FAN-ONLY MODE, etc. Think of how these items could create a malfunction or code condition.

Filter

95ZV72034

Recirculation filter

95ZV72032

If cooling or heating performance is poor, clean or replace the fresh air filter on the rear of the cab. Also clean the recirculation filter behind the seat.

65ZV-2 US 72-20 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Lever

Lever should be fully pushed down for max. recirculation.

95ZV72035

For maximum heating or cooling performance the system should be run in the “Recirculation” mode.

IMPORTANT Respirable dust can damage operator and cause components to break down. The machine should be run with the cab doors closed for operator to be protected from dust and to protect components from damage related to dirt impacting and becoming hard inside the evaporator and the heater coils.

65ZV-2 US 72-21 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Problem: No heat 1. Set temperature control knob of control panel to “Max Cool”. It is supposed to make water valve fully closed. Verify AC/Heater knob is turned to “Heater” (Combo control only). 2. Verify manual block valve (if present) at engine is open, and start engine for a few minutes. 3. Disconnect unit wire harness (33191-60540) and cab harness (33191-60520). Check power voltage at pin E (power) and pin B (ground) of cab harness connector. (a) If voltage is 24 V (may be slightly more, depending on the voltage from the vehicle), go to step 4. (b) If there is no voltage, check wire connection for both power and ground, from cab harness connector to vehicle harness. (c) If cab harness is fine, check fuses and harnesses of vehicle. Make sure end of ground line is properly fastened with fastener. 4. Remove cover from unit and feel both ends of hoses connected to water valve. (a) If inlet side is cold even after running the engine for a while, check inlet tube of heater coil. (a-1) If tube is not warm, check connection from engine to coil for any blockage. (a-2) If tube is warm, replace heater coil. (b) If inlet hose to water valve is warm outlet hose is cold, turn temperature control knob from “Max Cool” to “Max Heat”. (c) Check movement of coupling of water valve actuator. If no movement, check signal at pin 8 of water valve actuator. (c-1) If voltage is around 8.6 V, go to step (c-3). (c-2) If no voltage, check voltage at pin 8 of control panel. It should be 8.6 V at “Max Heat” and 3 V at “Max Cool”. - If voltage at pin 8 is correct, check wire connection from pin 8 of control panel to pin 8 of water valve actuator. - If voltage is not correct, replace control panel.

- If there is no voltage, check voltage at pin 2 of control panel. If 12 V is present, replace control panel. If no voltage at pin 2, check wire connection from pin 2 of control panel and pin 5 of PWM 1. If connection is fine, troubleshooting for blower is required. (c-3) Check voltage at pin 10 (12 V) and pin 7 (GND) of water valve actuator. - If voltage is 11.8 V, replace water valve assembly. - If no voltage, check wire connection from pin 10 of water valve actuator to pin 5 of PWM 1. PWM1 can be identified with the power wire marked with “PWR1”. - If the connection is fine, there could be a problem with PWM1. (Troubleshooting for blower is required.) (c-4) If actuator’s coupling rotates and outlet hose from water valve does not get warm, replace water valve assembly.

65ZV-2 US 72-22 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Problem: No cooling 1. Check for refrigerant leakage. (a) Check fittings for defect or damage. (b) Check service/switch ports. - Improper torque of fittings - Stem at fitting may be bent - Missing or misinstalled components? (c) Check O-rings installed with fittings. - O-rings should be properly positioned, flush with bulge in tube where they seat - Lubricated with refrigerant oil (PAG, not mineral) - Fittings must be tightened to correct torque - Damaged O-rings may cause failure - Missing O-rings may cause failure

(c) If not check AC clutch fuse and connections. (Found in relay box in machine.) - Check voltage on AC relay (45050-60070) pin 87. It should be around 24 volts to ground. - Check voltage on pin 30 and 85 of relay. It also needs to be around 24 volts. - Check connection and vehicle fuses. - Check pin 86 of the relay. Voltage should be less than 1 volt. - Check connection through low & high pressure and freeze switches, back to pin 7 on control panel. (d) Check AC relay control signal at pin 7 of control panel. The voltage should be less than 1 volt. - If no signal or more than 1 volt, replace control panel. - If no problem found, go to step 4. 4. Check condenser fans. (First check simple items like fan & fin condition. Is head pressure too high due to clogging or slow rotation?)

(d) Check hoses. - Hose bend radius must be correct to keep from blocking refrigerant - If a hose is touching other parts, it can take on heat and lose efficiency, or leak refrigerant - Contamination or material breakdown

(a) At pin 6 and 7 of vehicle harness, condenser fan output should be around 24 V*. If the voltage is not correct, check connections to condenser relay.

(e) If any leakage is detected, evacuate system, fix or replace parts and charge with proper amount of refrigerant.

(b) Check pin 30 and 86 of condenser relay to see if it is around 24 V*. - If not, check vehicle fuse and connections.

(f)

Note * Except for model 95ZV-2. It contains a 1 ohm resister that will reduce voltage slightly more.

If cooling problem continues, go to step 2.

2. Start engine. Verify AC/heater knob of control panel is turned to AC. (a) Check control functions 3. Check compressor and clutch. (a) Check clutch harness to see if it has been pinched or damaged. - If damage is found, replace harness if applicable (may have to replace compressor). (b) Make sure engine is running. If clutch is not engaging, check voltage output to clutch at pin 8 on vehicle harness. It should be approximately 24 volts DC with slight margin of variance.

(a) Check pin 85 of condenser relay. - If voltage is not less than 1 volt, verify connections back to pin 7 of control panel for AC clutch signal. If wiring is fine, replace control panel.

65ZV-2 US 72-23 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Problem: No blower or blower speed problem

Diagnostic step - Electrical circuit

1. Check voltage between pin B (GND) and pin E(PWR1) of unit harness 660765.

Damage to wiring connectors will result if incorrect methods are used to check circuits.

(a) If 24 volts present, go to step 2.

When accessing voltage readings, use pin inserts through the back of the electrical connector that permit access to voltage readings. See "Checking voltage at connectors" page 72-24 for an illustration showing how to correctly and incorrectly check the voltages are connectors.

(b) If not, check fuses and connection to vehicle. 2. Check voltage on pin 1 of blower motor connector (check both motors). (a) If 24 volts present, go to step 3. (b) If not, check power relays and PWM’s. (b-1) Check battery voltage on pin 30 and pin 85 of both power relays in reference to ground. (b-2) Check voltage of pin 86 of power relays. It should be less than 1 volt. (b-3) Check connection between pin 86 of power relay and pin 4 of matching PWM. (b-4) PWM might be defective. 3. Verify voltage on pin 2 of blower motors varying from 24 volts (blower off) to 0 volt (fully on) when blower speed control knob being turned. (a) If voltage does not change, check connection between pin 9 of control panel and pin 6 of both PWM’s. (a-1) If there is continuity between them, check signal voltage on pin 9 of control panel. It should change as blower speed control knob being turned. - If voltage on pin 9 does not change, control panel is defective. - If it changes, go to step (b). (b) Check signal voltage on pin 6 of PWM. Signal varies from 0 volt (off) to approximately 10 volts (which is fully on). (b-1) If signal voltage does not change, replace PWM.

65ZV-2 US 72-24 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Checking voltage at connectors Smoothly slide probe alongside terminal pins & make contact along pin.

Carefully insert probes along terminal pins as show.

K95V2U72015

Never do the following:

Always do the following:

1. Insert volt ohm test leads into the front side of the connectors.

1. Insert small electrical probes into the back of the connectors so as to access circuit by sliding the probes alongside the pin while it is still in the assembled connector.

2. Skin wires with a wire stripper or knife to expose copper to check the leads. 3. Blow connections with compressed air that contains moisture. This will lead to corrosion due to condensation. 4. Use cleaning solutions that may melt away plastic insulation or otherwise damage insulators or connectors.

2. Check to verify that you are working with the correct terminal number that is on the Deutsch electrical connector, and verify circuit in diagram and circuit that as is printed on wire; Then verify continuity with a continuity tester. 3. Carefully reconnect connectors so indexing tabs plug in correctly & do not cause incorrect circuit connections.

65ZV-2 US 72-25 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Checking actuators Water valve actuator check The water valve actuator and other actuators can be tested for performance. Use a digital volt ohm meter for this test. DO NOT USE AN ANALOG METER TO DO THIS PROCEDURE. It may load the electronic circuits and cause internal failures.

Water valve operation test. (When increasing temp. water turns "off" by increasing voltage & close valve.) Actuator should rotate freely. Opens with about 3 V DC / closes with about 8.6 V DC. Mid. is +/- 4.0 V DC.

Opened 2~3 V DC

R (Do not connect)

Closed 8.6 V DC

B B

Sweep is about 115º

K95V2U72014

The same process can be repeated for the other actuators that operate the ventilation damper doors. The actuators are for all practical purposes identical in their function and work on the same principal of operation. Use this test procedure when checking actuators.

65ZV-2 US 72-26 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Maintenance Helpful hints

Low pressure gas (suction side)

Hot high pressure gas

#10 Low pressure switch (LPS)

Outside air flow

Expansion valve (TXV)

Cold low pressure gas Cab air flow #8 Thermostat probe

Compressor

Metered refrigerant

Condenser

Evaporator

#6 High pressure switch (HPS)

High pressure liquid Receiver-drier

95ZV72021

General tips for working on A/C systems 1. Oil charge - Always look for, and refer to original manufacturer label on compressor. ALWAYS remove refrigerant charge to add oil, or check refrigerant oil level. Our Sanden holds about 240 CC* of oil. Note * - 8.1 fluid ounces SD5 compressor (33470-60120) - Model 95ZV-2 uses an SD7 compressor that has 5.9 fluid ounces (33470-60160) - Compressors usually come labeled with correct volume of oil needed. Compressor for R-134a uses PAG oil. - System should hold about 2 to 2 1/2 ounces of oil per pound of refrigerant in A/C system.

- Each 7-ft. section of hose will trap about 1 ounce of refrigerant oil. - Factor in to oil charge, that major components such as the receiver drier, condenser, evaporator, etc. will all hold about 2 ounces of oil each. - Some technicians choose to remove and measure oil in compressor. If this can be done in such a way so as to keep the oil from becoming contaminated, this is OK. But this should be done in a clean, dry environment.

65ZV-2 US 72-27 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050) 2. To check the operation of a thermal expansion valve (TXV), reduce temperature of the thermal expansion pod at the end of the thermal expansion valve, and see if the valve closes. This will be evident by the low-pressure switch (LPS) closing, and breaking circuit to the touch pad controller. 3. TXV’s should be matched to the system. - If you use a valve that is too small, it will usually be opening and closing much of the time, and will not regulate the refrigerant properly. Use the OEM TXV.

10. “Sight glass charging” is not an accurate way to charge, as ambient temperatures affect the amount of bubbles that you can see. This method of refrigerant does not provide optimal refrigeration by the A/C system. Instead of charging the system in this way, it is better to use weight, and then test for the temperature in the condenser about 2/3 the way through the core. With a thermometer placed in the condenser core, and a thermometer in the dash vent, you can determine system efficiency and either add or remove the refrigerant as needed*.

- If you use a valve that is too big, you will have a warmer than normal, inefficient evaporator.

Note * Run engine at about 1,200~1,600 RPM’s while doing this check.

4. Receiver driers should be serviced periodically. Kawasaki recommends that this be done every 3 years, or 6000 hours, when color changes from blue to pink or white in the moisture indicator, or every time the unit is evacuated and refilled.

11. Be careful when charging, not to “liquid charge”, as this reduces compressor life from attempting to compress a liquid. In particular, the reed valves and piston rings are especially subject to damage from this type of charging.

5. Condensers should always be kept free from plugging. Fans should be well maintained, and checked for operation. Fan blades should be kept in good condition. Fins should be maintained and not bent over. Pressure washers should be used with discretion.

12. We recommend that OEM parts be reinstalled in the A/C systems provided by Kawasaki. Other parts may not fit well, and affect overall performance of the system. Some parts may appear the same from the outside, but can even be plumbed wrong internally, and can cause the failure of other components due to retention of lubricating oil.

6. Evaporators and evaporator fans should be kept free of debris. They must have adequate airflow to keep the heat transfer to the refrigerant. Blocked evaporator cores tend to freeze faster than those that are not blocked. External contamination from dirt, etc. is often linked to the real problem. 7. Air inlets should be kept free from plugging, and filters maintained. 8. For proper operation of the thermostatic temperature switch, the unit must have sufficient airflow. A plugged evaporator core will freeze unnecessarily. This will create the environment for rapid on/off signal cycling to the controller. 9. Always refer to the refrigerant labels and fittings to charge the system. NEVER MIX ANY REFRIGERANT WITH ANOTHER REFRIGERANT. THE RESULT IS A GAS THAT MUST BE STORED AND DISGARDED WHEN THERE IS ENOUGH TO BE MOVED. IT IS AGAINST THE LAW TO IMPROPERLY DISPOSE OF REFRIGERANTS.

13. Values of switches are as follows. Switch Low pressure switch

On above 30 PSI, off below 10 PSI

High pressure switch

Off above 360 PSI, back on at 230 PSI

Thermostatic switch

[See table that gives values]

65ZV-2 US 72-28 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Basic tools needed to work on air conditioning Note that all tools must be compatible with the refrigerant being used. R134a, and R12 tools are NOT interchangeable. NEVER MIX REFRIGERANTS!

Manifold gauge set

95ZV72024

High side hose, RED

Low side, BLUE

Coupler

3. Refrigerant recovery and vacuum unit (must be EPA certified, and refrigerants must not be mixed).

Vacuum and charging line, YELLOW

Coupler 95ZV72025

Vacuum pump

4. Leak detector for R134a and R-12 gas.

Refrigerant container 95ZV72022

1. Manifold gauge set.

95ZV72026

5. Lubricating oils; Use mineral oil for R-12, PAG oil for R134a. 95ZV72023

2. Scale, (capable of accurately measuring an ounce).

65ZV-2 US 72-29 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Pressure temperature chart Deg. F

Deg. C

R-134a

-30

-34.4

*9.8

-25

-31.7

*6.9

-20

-28.9

*3.7

-15

-26.1

0.0

-10

-23.3

1.9

-5

20.6

4.1

-17.8

6.5

-15.0

9.1

-12.2

12.0

-9.4

15.0

-6.7

18.4

-3.9

22.1

-1.1

26.1

1.7

30.4

4.4

35.0

7.2

40.0

10.0

45.3

12.8

51.1

15.6

57.3

18.3

63.9

21.1

70.9

Deg. F

Deg. C

R-134a

23.9

78.4

26.7

86.4

29.4

94.9

32.2

103.9

35.0

113.5

100

37.8

123.6

105

40.6

134.3

110

43.3

145.6

115

46.1

157.6

120

48.9

170.3

125

51.7

183.6

130

54.4

197.6

135

57.2

212.4

140

60.0

227.9

145

62.8

244.3

150

65.6

261.4

155

68.3

279.5

160

71.1

298.4

165

73.9

318.3

170

76.7

342.0

180

82.2

385.9

All pressure values (except as noted) — PSI in HG * Denotes values in — in. Hg Vacuum (mercury)

What do you know about temperature? WHAT is more relaxing than stepping into a warm shower or bath on a chilly day? But if the water is too hot or too cold, you may feel discomfort and spend as little time bathing as possible. What makes taking a shower or a bath a pleasant experience instead of a shock? Of course, it is the temperature of the water. The temperature of the air outside is also an everyday concern. Knowing the temperature helps us decide how to dress and how to plan our day. Since knowledge of the temperature is so useful, public buildings often display it along with the time. Yet, depending on where you live, the number displayed may reflect entirely different conditions. Why, for example, would a reading of 40 degrees in the United States call for donning a coat, whereas a 40- degree reading in Europe would call for the lightest possible clothing?

65ZV-2 US 72-30 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Temperature scales Very simply, where the Fahrenheit scale is used, such as in the United States, 40 degrees is cold, not far above the freezing point of water. But in Europe, where the Celsius scale is commonly used, 40 degrees registers a temperature that is swelteringly hot. In this article we will only consider these two scales used by the general public. Where did the Fahrenheit and the Celsius temperature scales come from? In 1714 Gabriel Daniel Fahrenheit, a German physicist, used a mercury thermometer to devise a temperature scale. He determined three fixed points. He wanted the zero point on his scale to be as low as possible. So he mixed ice, water, and a kind of salt, and the temperature of the mixture dropped down to the lowest point he could then obtain. That temperature became 0 degrees on his scale. After that, Fahrenheit selected the temperature of a healthy human body as the upper point on his scale. He set this temperature at 96 degrees. (However, since then the body temperature of a healthy human has been found to be about 2 1/2 degrees higher than what he arbitrarily set.) To obtain the third fixed point, he measured the freezing point of water and found it to be 32 degrees. Later, the scale was applied to the boiling point of water. The temperature turned out to be 212 degrees at sea level, which Fahrenheit later proposed as the upper point on his new scale. A contemporary of Gabriel Fahrenheit was Anders Celsius, a Swedish astronomer, who lived from 1701 to 1744. In 1742 Celsius devised a temperature scale that is also identified by its inventor’s name. The scale is based on two fixed points: 0 degrees is the freezing point of water, and 100 degrees is the boiling point of water at sea level. Since Celsius divided his thermometer into 100 equal parts, it is also known as the centigrade temperature scale. The Celsius scale is used wherever metric units have become accepted. Since both the Fahrenheit and Celsius scales are in common use today, it is often necessary to convert from one to the other. How is this done? Well, note that the difference between the boiling point and the freezing point of water on the Fahrenheit scale is 180 degrees (212 degrees minus 32 degrees). But on the Celsius scale, it is 100 degrees. Therefore, the ratio between the two scales is 180/100, or 9/5.

Thus, to change from Fahrenheit to Celsius, first subtract 32 from the Fahrenheit temperature. Then multiply the difference by 5/9. As an example, say the Fahrenheit temperature is a sweltering 104 degrees. To arrive at the Celsius temperature, subtract 32 from 104, which gives 72. Then multiply 72 by 5/9. The result is 40, which is the Celsius temperature. Indeed, 40 degrees Celsius is sweltering! On the other hand, to change from Celsius to Fahrenheit, you need to multiply the degrees Celsius by 9/5 and then afterward add 32. So, as an example, say the temperature is 20 degrees Celsius. What does that equal on the Fahrenheit scale? Multiplying 20 by 9/5, you get 36. By adding 32 to 36, you arrive at the Fahrenheit temperature of 68 degrees.

65ZV-2 US 72-31 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

What is temperature?

Temperature ranges

Temperature is a measure of hotness and coldness. But what makes a substance hot or cold? If you could peer into the molecular and atomic structure of materials as they heat up, you would see various changes taking place. Consider a pan of water as heat is applied to it on a stove.

As far as is known, temperature does not have an upper limit. On the other hand, it does seem to have a lower limit. Absolute zero has been set at -459.67 degrees Fahrenheit, or -273.15 degrees Celsius. This is the point at which molecules and atoms of a substance have the least possible energy.

The water molecules move faster and faster. Soon the water boils. This occurs when the water molecules are moving so fast that they bounce off one another and no longer stick together in liquid form. The water is actually beginning to change into a gas, which we see as steam.

The surface of the planet Pluto has an estimated temperature of about -350 degrees Fahrenheit, or -210 degrees Celsius. In 1965 astronomers learned that the blackness of outer space has a temperature of about -455 degrees Fahrenheit, or -270 degrees Celsius, just 3 degrees above absolute zero on the Celsius scale. Toward the other extreme, the center of the sun is believed to be about 15 million degrees Celsius. But stars larger than the sun–and there are stars thousands of times larger–probably have much higher temperatures.

Bubbles of gas form first at the bottom of the pan, since the temperature there is the highest. Even though heat is continually added during this transformation of water into steam, the temperature does not change. This is because it takes energy to break the molecules free from the liquid state and transfer them to the gaseous state. The added heat supplies that energy. So instead of making the water hotter, it simply causes more water molecules to change to the gaseous state. The water molecules in the gaseous state move faster and faster, vibrating and shifting position with temperature increases. If the temperature of the steam was raised extremely high, say into the tens or hundreds of millions of degrees, even the electrons would be stripped off the atoms. At such high temperatures, the nuclei, the tiny cores at the center of atoms, would strike one another so hard that nuclear reactions could take place. In fact, this is the idea behind the goal of using nuclear fusion to generate power.

What about temperature ranges here on earth? They fluctuate in a relatively narrow range. In Antarctica a temperature of -128.6 degrees Fahrenheit, or -89.2 degrees Celsius, was measured on July 21, 1983. And a record high temperature of 136 degrees Fahrenheit, or 58 degrees Celsius, was registered at El Azizia, Tripolitania, in northern Africa on September 13, 1922. But the vast majority of humans have not experienced temperatures even approaching those extremes. Fahrenheit

Celsius

212

100

Water boils at sea level atmospheric pressure

98.6

Normal body temperature

Water freezes

-40

Point when degrees Celsius is same as degrees Fahrenheit

-460

-273

Absolute zero

65ZV-2 US 72-32 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

A/C Charging

Preliminary system check

Disclaimer

1. Perform a visual inspection of the system.

Charging of a refrigerant system should be done by a certified technician. The refrigerant system is under pressure. An accidental release of refrigerant can cause rapid freezing of skin or eyes. Federal law prohibits the intentional release of refrigerant to the atmosphere.

- Check that all hoses are routed and connected properly. - Check compressor and v-belt. 2. Perform electrical check. - Turn ignition key to on. - Check for proper control operation.

General charging procedure Following is one method to charge a “new” ac system.

Equipment used 1. R-134a manifold gauge set 2. Vacuum pump for automotive R-134a system 3. Electronic scale (5-100 lb. range, accurate to 0.5 ounce.) 4. Refrigerant R-134a (High quality refrigerant is recommended.) 5. Refrigerant oil Compressor manufacturers recommended. 6. Electronic leak detector. Note Charging procedure may vary with the use of other types of equipment.

- Check for blower and condenser fan operation. - Clutch may not engage if system has a low pressure cut out switch. 3. If it is now that additional refrigerant oil needs to be added now may be a good time to add it. - Oil can be added directly into a port on the compressor or during the charging operation.

65ZV-2 US 72-33 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Leak check

Charge amounts

1. Connect manifold gauge set to the system.

The factory refrigerant charge for all Kawasaki ZV-2 wheel-loaders with the Bergstrom A/C system is 4 pounds and 4 ounces (4.25 lbs., 1.93 kg) by weight.

2. Connect vacuum pump to gauge set. Open valves. Turn on pump and evacuate to 29.2 HG. 3. After fifteen minutes, close valves and note vacuum pressure. 4. If after 10 minutes, the pressure has not changed, evacuate system for a minimum of 30 minutes longer. If the vacuum reading has changed, the system has a leak. A token R-134a charge can be added to the system to detect leaks with an electronic leak detector. Note It is highly recommended that a micron scale vacuum gauge be used. It can indicate whether the vacuum pump is capable of pulling a deep vacuum which is needed to remove moisture from the system and it can also indicate leaks or the presence of water. When used properly the gauge can reduce the time required for evacuation.

Procedure 1. After the system has been properly evacuated and leak checked close both high and low manifold gauges valves, and disconnect the vacuum pump. 2. Connect the yellow hose to refrigerant canister. Open valve on canister. Loosen the fitting at the manifold gauge set to purge air from the yellow line then retighten. 3. Place canister on scale and record weight. 4. Open both valves on the gauge set to allow refrigerant into the system. DO NOT start engine at this point! You are filling a static system. 5. When the refrigerant flow stops, close the high side valve and start the engine. Set A/C control to high fan and coldest setting. 6. When the proper weight of refrigerant has been drawn into the system close the valve at the refrigerant canister and then at the manifold gauge set.

The specified compressor Sanden model 4516 is pre charged with enough refrigerant oil for the system. Oil charging a “old” system requires knowledge of oil loss history of the system.

65ZV-2 US 72-34 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Final inspection Final inspection should consist of inspecting all components for correct installation and checking performance after the machine and A/C system has been operated for a minimum of 15 minutes.

General inspection points 1. Check for loose hardware. 2. Check for shifting of hoses and wire harnesses. 3. Check duct hose clamps. 4. Check compressor V-belt tension. - For “hot” belt re-tension if under 50 lbf. - For “cold” belt re-tension if under 90 lbf. 5. Check for heat valve bypass. 6. Check for proper condensate drainage. 7. Check system operating pressures and louver temperature. - See table in index for common operating values.

Power on/Power off the blower

Blower control

K95V2U72016

Turn the blower control clockwise to turn on the blower. Turn the blower control fyully counterclockwise to turn off the blower.

65ZV-2 US 72-35 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Appendix Table 1: Abbreviations ABBREVIATIONS OF TERMS USED ATC

Automatic temperature controller

Right hand

Left hand

ACU

Air conditioning unit

Low pressure

High pressure

Electric condenser

A/C

Air conditioning

Assem. or Assy

Assembly

65ZV-2 US 72-36 72 Function & Structure Operator Station Group Air Conditioner (S/N 5001~5050)

Table 2: General air conditioning system operating parameters A/C system operating parameter chart Following are general guidelines for A/C system operating parameters for use on TXV systems with fixed airflow condensers. Ambient temperature

Min. discharge pressure

***Max. discharge pressure

Min. suction pressurelow idle

Max. suction pressurehigh idle

**Max. louver temperaturelow idle

ºF

psig

ºF

107

123

140

111

158

125

179

140

200

156

224

100

173

250

105

192

278

110

212

308

115

234

340

120

257

375

125

282

412

Overcharge; Poor heat transfer at EC.

Undercharge

Overcharge; defective compressor

Undercharge; defective *Possible causes: compressor; Poor heat transfer at evaporator

*See an A/C Service Manual-Troubleshooting for addition causes. **Louver temperature is highly dependent on humidity level. Measure as close to the evaporator coil as possible. At high idle louver temperature should drop 4-10ºF. ***At low ambient temperature, clutch cycling may occur and at high ambient the high pressure cut out switch may prevent steady state conditions. ****There are many things that can change these values. Humidity levels, atmospheric pressure, quality of maintenance of the machine, elevation, etc. are all items that can alter these values.

Standard conditions Set controls to Hi Fan, Maximum cool. Check that heat valve is off and functioning properly. Operate A/C with door/windows open for minimum of 5 minutes. Check readings at Steady state conditions.

65ZV-2 US 72-37 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Air Conditioner (S/N 5051~) Denso air conditioner components

4 1-1

3 1-2

1 7 9

6 13

97ZV72020

1. Air conditioner assembly 1-1 Cooling unit assembly 1-2 Blower assembly 2. Air distributor assembly 3. Recirculating air filter 4. Control panel 5. Condenser assembly 6. Compressor assembly 7. Receiver drier 8. Receiver drier bracket 9. Joint 10. Drain hoses 11. Relay 12. Thermistor* (inside air sensor) 13. Thermistor* (outside air sensor) 14. Solar sensor (insolation sensor) * or thermal resistor

Air conditioner specifications (system performance) Cooling system performance Cooling capacity

4.65 kw (15,881 BTU) ± 10%

Air quantity

550 m3/h (720 yd3/h) ± 10%

Rated voltage

DC 24 V

Power consumption

345 W (14.4 amps) ± 10%

Heating system performance Heat radiation quantity

5.2 kw (17,759 BTU) ± 10%

Air quantity

380 m3/h (500 yd3/h) ± 10%

Rated voltage

DC 24 V

Power consumption

170 W (7.1 amps) ± 10%

(Difference in temperature: 65ºC, water flow rate: 6 L/min)

65ZV-2 US 72-38 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Denso air conditioner structure Cooling unit 37

14 57

38 13 25

50 49 24 1

9 24

23 6

5 15 4

3 16 12

97ZV72021

65ZV-2 US 72-39 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

1. Cooling unit case (rear) 2. Cooling unit case (front) 3. — 4. Evaporator core 5. Heater core 6. Expansion valve 7. — 8. Tube 9. De-icing sensor (thermal resistor) 10. — 11. Door (upper) 12. Door (lower) 13. Door (foot) 14. Damper (vent) 15. Pressure switch (triple) 16. Liquid tube 17. Suction tube 18. — 19. —

20. — 21. — 22. — 23. Power integrated circuit assembly 24. Servo motor (A/M, air mixing) 25. Servo motor (mode) 26. — 27. — 28. — 29. — 30. — 31. — 32. — 33. — 34. — 35. — 36. — 37. Lever (face, door) 38. Lever (foot, door)

39. — 40. — 41. — 42. — 43. — 44. — 45. — 46. — 47. — 48. — 49. Lever (face, front) 50. Control lever (face, front) 51. Door (S/A) (face, front) 52. — 53. — 54. — 55. — 56. — 57. Thermo sensor (water temperature)

65ZV-2 US 72-40 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Heater and accessories

Air distributor (hood & defroster selection box) 13 3 6

7 2

7 2 5 1 1 97ZV72024

11 17

97ZV72023

1. Blower case 2. Blower case 3. Air damper case 4. Air damper case 5. Blower & blower motor 6. Servo motor 7. Door 8. — 9. — 10. Bracket 11. Pipe (for cooling motor) 12. — 13. — 14. — 15. — 16. — 17. Relay

1. Air damper case 2. Air damper case 3. — 4. — 5. — 6. Control lever 7. Door 8. — 9. Control lever 10. — 11. — 12. — 13. Servo motor actuator (AY, inside/outside air)

65ZV-2 US 72-41 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Air compressor (with magnetic clutch)

2-1 2

2-2

2-3

2-6

2-8 5~7 2-7 1 85V2U72001

3. — 4. — 5. Plate washer 6. Plate washer 7. Plate washer

1. Compressor 2. Magnetic clutch assembly 2-1 Magnetic stator coil 2-2 Magnetic clutch pulley 2-3 Clutch hub 2-6 Plate washer 2-7 Snap ring 2-8 Snap ring

Condenser unit 3 1

4 2

1. Condenser core 2. Blower assembly 3. Condenser bracket 4. Condenser bracket 5. — 6. —

7. Cover 8. — 9. — 10. Wire harness 11. — 12. Resistor

95V2U72001

65ZV-2 US 72-42 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Control unit

Control amplifier

Control panel

97ZV72027

Control panel

OFF switch

Inside/outside air selector switches

Blower switches

Temperature setting switches

Liquid crystal display (LCD) unit

Vent mode selector switch

AUTO switch

Air conditioner ON/OFF switch

97ZV72028

65ZV-2 US 72-43 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Function of cooling mechanism Principle of cooling

Indoor

Evaporator

Expansion valve

Expansion Evaporation Condensation

Deprives heat of the adjacent area.

Condenser Releases heat to the outside.

Compression Refrigerant

Compressor Basic cooling cycle

contain some minor gas fractions, it is routed into the receiver drier. There it dries the refrigerant by use of a material we term a "desiccant", which means drying agent. A down tube in the receiver drier is submerged into the heavier liquid that is now at the bottom of the receiver drier. This tube will permit passage of only the heavier liquid that is at the bottom of the receiver drier. Then the high-pressure liquid passes through the thermal expansion valve that provides a restriction or throttles the flow of refrigerant. This restriction reduces the pressure of the liquid refrigerant thus reducing its boiling point. The expansion valve also meters the amount of refrigerant to the evaporator, by modulating the valve from wide open to closed, which varies with the heat load. The expansion valve separates the high-pressure side from the low-pressure side.

97ZV72029

Function and operation of air conditioning system Very often, things are much simpler than they may appear. This is also the case with an air conditioning system. Gas when compressed often heats as a result of molecular compression, and when decompressed it cools. Some gases are more prone to heat or cool to a greater degree when undergoing these changes than are others. We use these natural laws to make an air conditioning system work. Another factor to take into consideration is that we enhance the natural effects of hot and cold in these refrigerants by manipulating the gas temperature while it is undergoing the heating or cooling process. Note HFC 134A is a very effective "vehicle" to carry away heat. Explanation of function of air conditioning unit. As an example of manipulating refrigerant temperatures, imagine that you can very quickly make the refrigerant intensely hot. This is done by use of a compressor, as we just mentioned in paragraph one. If you course the heated refrigerant that just came from the compressor through a condenser that will cool it while it is very hot and in a compressed gaseous state, you will make it shed some of its heat that it gained in the compression process. This refrigerant then is converted into a liquid at this point, while still in the condenser. This is why it is called the condenser, as it has condensed the gas into a liquid. As a liquid that may still

The refrigerant is now at the evaporator. Temperatures in the evaporator are cold enough to cause the ambient air to cool when blown through it. This causes condensation to happen. The fan-charged air that rushes through the evaporator is now going to shed its humidity. This humidity, or condensed water, is routed through some tubing to be discharged to the outside of the cab as waste water that falls to the ground. The refrigerant is now on its way back to the compressor. It is still under pressure when compared to the atmospheric air pressure. However, because it is drawn along by the refrigerant compressor suction, we now say that is in the suction side (low-pressure side) of the circuit.

65ZV-2 US 72-44 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Refrigerant A liquid object which circulates inside cooling circuit and transmits heat is called "refrigerant". The refrigerant changes repeatedly its state, from "liquid --> gas --> liquid --> gas ...", and carries heat from the low temperature side (inside the cab) to the high temperature side (outside the cab) while changing its status. There are many types of refrigerants. This air conditioner adopts refrigerant R134a which does not contain chlorine and does not destroy the ozone layer.

IMPORTANT Make sure to use the specified refrigerant (R134a). If any other refrigerant is used, following problems may occur: - The air does not become cool enough. - The equipment may be damaged. And never mix R134a with any other refrigerant. Chemical formula

CH2FCF3

Molecular weight

102.03

Boiling point

-26.19ºC (-15ºF)

Critical temperature

101.14ºC (214ºF)

Critical pressure

4.1 MPa (41.45 kgf/cm2) (595 psi)

Critical density

511 kg/m3 (0.073 lbs)

Density of saturated liquid (at 25ºC/77ºF)

1,206 kg/m3 (595 psi)

Specific volume of saturated vapor (at 25ºC or 77ºF) Latent heat of evaporation (at 0ºC/32ºF) Combustibility Ozone decomposition modulus

0.0310 m3/kg 197.54 KJ/kg (186 BTU) (47.19 kcal/kg) Noncombustible 0

65ZV-2 US 72-45 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Refrigerant characteristics

Generally, fluid (which is the generic name for compressed / condensed non-gas liquid) has following properties.

Refrigerant temperature (ºC) (ºF)

100 (212)

1. When the temperature of gas at a certain pressure decreases, the gas starts to condense and change into liquid at a certain temperature. For each substance (liquid), this temperature is fixed at a given pressure. This temperature determined by a given pressure is called the "saturated temperature".

80 (176) 60 (140) 40 (104) 35 (95) 20 (68) 15 (59) 0

(

20 4)

(

30 22) 0

3.6 5 8 10 353 490 785 981 51 71 114 142

15 1,471 213

20 1,961 284

25 2,452 355

30 2,942 426

35 3,432 497

Gauge pressure (kgf/cm2G) Relationship between saturated pressure and saturated temperature of R134a

40 (kgf/cm ) 3,923 (kPa) 568 (psi)

85V2U72002

2. On the contrary when the temperature is determined, the pressure at which liquefication starts is fixed. This pressure is called the "saturated pressure". The figure on the left shows the relationship between the saturated temperature and the saturated pressure of refrigerant R134a. At the temperature and the pressure below at the lower right side of the curve, the refrigerant is liquid. At the temperature and the pressure above at the upper left side of the curve, the refrigerant is gas. Suppose that the air conditioner is used in mid summer. When evaporated, the refrigerant absorbs the heat of evaporation from the air inside the cab. Accordingly, in order to cool down the air inside the cab to approximately 25ºC (77ºF), the refrigerant should change (be evaporated) from liquid into gas at a temperature lower than 25ºC (77ºF). From the figure, it can be seen that the refrigerant R134a can sufficiently cool down the air inside the cab at a pressure above the atmospheric pressure. (If used refrigerant requires a pressure below the atmospheric pressure to cool down the air to the necessary temperature, air enters into the circuit and the ability of the cooler is diminished.) In the process at which the vaporized refrigerant is condensed to liquid, the refrigerant is cooled down by outside air of about 35ºC (95ºF) so that it can condense. Accordingly, as is seen from the figure, the refrigerant can be liquefied at the pressure of 785 kPa (8.0 kgf/ cm2G) (114 psi) or more.

65ZV-2 US 72-46 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Cooling circuit

The figure on the left shows the cooling circuit of the air conditioner.

Inside cab

Pressure bulb

Expansion valve

Evaporator Blower

Inside engine room

Compressor

Cooling fan Pressure switch

Receiver dryer Condenser

In this circuit diagram, the area which cools down the air inside the cab is the evaporator. The cooling circuit utilizes the fact that the refrigerant absorbs heat (latent heat of evaporation) from the adjacent area when evaporated, and cools down the air inside the cab. The area where the refrigerant is evaporated is the evaporator. The "cooling" effect can be obtained only when the air to be cooled down is continuously fed to the area around the evaporator by the blower fan and the liquid refrigerant (wet evaporation refrigerant with low degree of dryness) is supplied into the evaporator. For example, in order to cool down the air to 15ºC (59ºF), the refrigerant can absorb the latent heat of evaporation from the air only when it is evaporated at a temperature lower than 15ºC (59ºF). It can be seen from the figure in the previous page that the pressure of the refrigerant inside the evaporator should be 353 kPa (3.6 kgf/cm2G) (51 psi) or less to realize it. And in order to keep sufficient cooling effect, the supplied refrigerant quantity should be adjusted so that the refrigerant supplied to the evaporator is completely evaporated inside the evaporator into dry vapor or gas.

Structure of cooling circuit 85V2U72003

Accordingly, the cooling circuit should be constructed to reduce the pressure inside the evaporator and supply proper quantity of refrigerant into the evaporator so that the evaporator can cool down the air sufficiently. The supplied refrigerant quantity is adjusted by the expansion valve. The pressure inside the evaporator is kept at a low value by the closing action of the expansion valve and the suction action of the compressor. The compressor works as a pump which circulates the refrigerant. The refrigerant in the dry vapor status returns into liquid by the compression action of the compressor and heat change (heat radiation) of the condenser, which acts to change the state of the gas to liquid.

65ZV-2 US 72-47 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Electrical circuit Control schematic drawing

Outside air sensor

Input signals

Set temperature, room temperature, water temperature, air temperature after evaporator

Insolation sensor Outside air sensor

e = Inside air temperature - Set temperature

Insolation sensor

Set temperature correction

Freeze sensor

Water temperature sensor

BLC Temperature control servo HOT Blower motor Temperature control servo

Blow-off servo

Warm-up control

Blower voltage

Water temperature (ºC)

Blower voltage/temperature control/blow-off servo motor position determination

Inside air sensor

COOL FACE B/I FLOOR Y value

Blow-off servo Compressor ON-OFF ON 3

Freeze sensor temperature (ºC)

95ZVE72018

65ZV-2 US 72-48 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Air conditioner functions of components Control panel Name and function of each part on control panel (1) OFF switch

Indicator lamps

(2) Blower switches

(6) Inside/outside air selector switches

(3) Temperature setting switches

(7) Liquid crystal display (LCD) unit

- (1) OFF switch This switch stops the operation of the blower and the air conditioner. When OFF switch (1) is pressed, the set temperature and the air blow quantity displayed on LCD unit (7) as well as the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) turned "off", and operation is stopped.

(4) Vent mode selector switch

Indicator lamps

(5) AUTO switch

(8) Air conditioner ON/OFF switch

97ZV72036

- (2) Blower switches These switches change over the air flow quantity in six steps. The air flow quantity is displayed on the LCD unit. When the switch is pressed, the air flow quantity increases. When the switch is pressed, the air flow quantity decreases. In the automatic mode, the air flow quantity is automatically changed over. Display on the LCD unit and the air blow quantity Display on LCD unit

Air blow quantity Air quantity "low" Air quantity "medium 1" Air quantity "medium 2" Air quantity "medium 3" Air quantity "medium 4" Air quantity "high"

65ZV-2 US 72-49 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) - (3) Temperature setting switches These switches set the temperature inside the cab in the range from 18.0ºC (65ºF) to 32.0ºC (90ºF). When the switch is pressed, the set temperature increases. When the switch is pressed, the set temperature decreases. Usually, set the temperature to 23~25.0ºC (72~77ºF). Display on the LCD unit and the function Display on LCD unit

Set temperature

18.0ºC (65ºF)

Maximum cooling

18.5~31.5ºC (65~95ºF)

Temperature inside cab is controlled so that set temperature is realized.

32.0ºC (90ºF)

Maximum heating

- (4) Vent mode selector switch This switch changes over the vent mode. When vent mode selector switch (4) is pressed, the vent mode displayed on LCD unit (7) is changed over, and air is blown from the displayed vent positions. In the automatic mode, the vent mode is automatically changed over. Display on LCD unit

Vent mode

Vent positions (A)

(B)

Face (blow-off to upper portion of body mainly during cooling)

○

Face & foot

○

Foot (blow-off to feet mainly during heating)

(C)

(D)

Remarks

○

Foot & defroster

○

Defroster

○

This mode is not selected in automatic mode.

○

This mode is not selected in automatic mode.

- (5) AUTO switch This switch automatically changes over the air blow quantity, the vent mode and the inside/outside air in accordance with the set temperature. When AUTO switch (5) is pressed, the indicator lamp above it lights. Usually, press this switch, set the temperature by using temperature setting switches (3), and use the air conditioner in the automatic mode.

When the automatic mode is changed over to the manual mode, the indicator lamp above AUTO switch (5) is extinguished. In the manual mode, the air blow quantity, the vent mode and the inside/outside air can be changed over by manipulating each switch.

65ZV-2 US 72-50 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) - (6) Inside/outside air selector switches These switches change over inside air circulation and outside air entry. When an either switch is pressed, the indicator lamp above it lights to indicate the selected air flow status. In the automatic mode, outside air introduction and inside air circulation are automatically changed over. Inside air recirculation

Outside air entry

The outside air is shut down, and the air inside the cab is circulated. Press this switch to rapidly cool or heat the air inside the cab or when the outside air is dirty. The outside air enters the cab. Press this switch to introduce clean air into the cab or defog the windows.

- (7) Liquid crystal display (LCD) unit This LCD unit indicates the set temperature, the air flow quantity and the vent mode during operation. When the OFF switch (1) is pressed, the set temperature and the air flow quantity are extinguished and the operation is stopped. - (8) Air conditioner ON/OFF switch This switch turns on and off the air conditioner (cooling or dehumidification/heating). When this switch (8) is pressed, the air conditioner is turned on and the indicator lamp above the switch lights. When this switch is pressed again, the air conditioner is turned off and the indicator lamp is extinguished. However, the air conditioner is turned on only while the blower is operating (that is, while the air blow quantity is displayed on the LCD unit.)

65ZV-2 US 72-51 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Operating method

2. Stopping the automatic operation

Normal use 1. Automatic operation

Set temperature

(1) OFF switch

(3) Temperature setting switches

(5) AUTO switch

97ZV72041

Air flow quantity

(8) Air conditioner ON/OFF switch 97ZV72040

(a) Set AUTO switch (5) to ON. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit, and that the indicator lamps above AUTO switch (5) and the air conditioner ON/OFF switch (8) are lit. (b) Adjust temperature setting switches (3), and set arbitrary temperature. The air conditioner automatically changes over the air flow quantity, the vent mode and the inside/outside air to realize the set temperature. Note When the vent mode is set to or in the automatic operation, if the engine water temperature is low, the air flow quantity is restricted to prevent blow-off of cold air.

Press OFF switch (1). Then, the set temperature and the air flow quantity displayed on the LCD unit are extinguished, the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) are extinguished, and the operation is stopped.

65ZV-2 US 72-52 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) 4. Stopping the manual operation

3. Manual operation

(2) Blower switches

(3) Temperature setting switches

(6) Inside/outside air selector switch

(4) Vent mode selector switch

(1) OFF switch

(8) Air conditioner ON/OFF switch 97ZV72042

97ZV72041

(a) Press blower switches (2), and adjust the air flow quantity. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit.

(b) Set to ON air conditioner ON/OFF switch (8). Confirm that the indicator lamp above the switch lights. (c) Adjust temperature setting switches (3), and set arbitrary temperature. (d) Press vent mode selector switch (4), and select arbitrary vent mode. (e) Press an either inside/outside air selector switch (6) to select inside air circulation or outside air entry.

65ZV-2 US 72-53 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) 2. Defroster operation

Other uses 1. Head cooling, feet heating (bi-level) operation

(2) Blower switches

(4) Vent mode selector switch

(4) Vent mode selector switch (2) Blower switches

(5) AUTO switch

(6) Inside/outside air selector switch (6) Inside/outside air selector switch

(3) Temperature setting switches 97ZV72044

(a) Press blower switches (2), and adjust the air flow quantity. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit. (b) Press vent mode selector switch (4), and display the vent mode on the LCD unit. (c) Set to ON air conditioner ON/OFF switch (8). Confirm that the indicator lamp above the switch lights.

(3) Temperature setting switches 97ZV72045

(a) Press blower switches (2), and adjust the air flow quantity. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit. (b) Press vent mode selector switch (4), and display the vent mode or on the LCD unit. (c) Set outside air introduction selector switch (6). (d) Press temperature setting switches (3), and display the set temperature "32.0" (maximum heating status) on the LCD unit.

(d) Arbitrarily set blower switches (2), temperature setting switches (3) and inside/outside air selector switches (6).

Adjust the louver at each vent position so that air flow reaches the windows.

Then, the air conditioner realizes the bi-level operation in which cold air is blown to the head and hot air is blown to the feet.

When defogging the windows or dehumidifying the air inside the cab in rainy season, set air conditioner ON/ OFF switch (8) to ON.

65ZV-2 US 72-54 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Other functions

3. Failure code deletion

Self-diagnosis function Each sensor and equipment used in the air conditioner can be diagnosed for failure.

(1) OFF switch

After completing the inspection and/or the repair, delete the failure codes memorized in the computer. If not removed, the failure codes memorized in the computer continue to display on the LCD whenever diagnosing. To delete the failure codes, press and hold both air intake control switches (6) for 3 seconds or more. <Display on the LCD unit and the failure mode> Display

(6) Inside/outside air selector switches

(3) Temperature setting switches Press and hold both the " " and " " switches together 97ZV72035 (for 3 seconds or more).

1. Press the OFF switch to stop the operation. (The set temperature and the air flow quantity displayed on the LCD are extinguished.) 2. When both temperature setting switches " " and " " (3) are pressed and held together for 3 seconds or more, the failure mode is displayed on the LCD unit. (a) If two or more failure are detected, the displayed contents can be scrolled through by pressing either one of temperature levels (3) " " or " ". (b) Press OFF switch (1) again to finish the self diagnosis function and return to the normal display.

Failure mode

E-

No failure

E11

Wire breakage in inside air sensor

E12

Short-circuit in inside air sensor

E13

Wire breakage in outside air sensor

E14

Short-circuit in outside air sensor

E15

Wire breakage in water temperature sensor

E16

Short-circuit in water temperature sensor

E18

Short-circuit in insolation sensor

E21

Wire breakage in vent sensor

E22

Short-circuit in vent sensor

E43

Abnormality in vent damper

E44

Abnormality in air mixing damper

E45

Abnormality in inside/outside air

E51

Abnormality in refrigerant pressure

Celsius-Fahrenheit selector function for the set temperature display While the blower is operating, press and hold both temperature setting switches (3) " " and " " together for 5 seconds or more to change over the unit of the displayed value between Celsius and Fahrenheit. However, the unit type (C or F) itself is not displayed. Only the set value is displayed. Value displayed on LCD unit Celsius (ºC)

18.0~32.0

Fahrenheit (ºF)

65~90

65ZV-2 US 72-55 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Air conditioner unit

Air mixing damper

[In the case of maximum cooling] Air mixing damper A (completely opened) Heater coil Evaporator coil

Cold air Co ld

air

Air mixing damper B (completely closed) [In the case of maximum heating] Air mixing damper A (completely closed)

Ho ta ir

Blower motor Inside/outside air selection damper Air mixing damper A

ld air

Inside air

Outside air

Fan

Blower motor Heater radiator

Evaporator Air mixing damper B

80ZVE72001

The air conditioner unit has the cooling, heating and air blowing functions to perform conditioning of the air inside the cab, and consists of an evaporator which cools down the air, a heater radiator which warms the air and a blower motor which blows the air. The temperature in the vent position is adjusted when the opening/closing position of the air mixing damper is so controlled that the cooled air while passing through the evaporator and the warmed air while passing through the heater radiator are mixed. The air mixing damper is controlled by the servo motor for air mixing assembled in the unit.

Air mixing damper B (completely opened)

80ZVE72002

During maximum cooling, the air mixing damper B is completely closed, and the air mixing damper A is completely opened. As a result, the air cooled by the evaporator does not go through the heater radiator but is blown off. During maximum heating, the air mixing damper A is completely closed, and the air mixing damper B is completely opened. As a result, all the air which has gone through the evaporator goes through the heater radiator, then the warmed air is blown off.

65ZV-2 US 72-56 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Evaporator

(7)

(5)

Evaporator

The evaporator is an important heat exchanger which evaporates liquid refrigerant set to low temperature and low pressure by an expansion valve, utilizes its latent heat, and absorbs heat from air (target) inside the cab. Accordingly, heat should be smoothly transmitted between the target and the refrigerant in the evaporator.

(4)

For this purpose, fins are provided on the air side of the evaporator to extend the heat transmission area on the air side so that heat can be smoothly transmitted between the refrigerant and the air.

(2)

By cooling, the moisture contained in the air condenses, changes into water drops, and adheres to the outside of the evaporator. If these water drops are frozen, the cooling effect deteriorates. To prevent this, attention should be paid also to proper drainage of condensed water.

(8) (1)

(6)

The refrigerant quantity supplied to the evaporator is adjusted by the expansion valve described next. In order to ensure that the refrigerant quantity is accurately adjusted, pressure drop of the refrigerant inside the evaporator should be minimal.

(3)

Refrigerant flow inside evaporator ( From expansion valve(1) to (8) Compressor

)

Accordingly, reduction of pressure drop is an element to enhance the performance of the evaporator. 97ZV72048

Troubleshooting the evaporator Item

Symptom

Cause

Gas leak

Both high pressure and low pressure are low, and air bubbles can be seen through sight glass.

- Joint portion of supply area - Cracks in evaporator main body

- Tightening - Repair/replacement

Blockage in circuit

Both high pressure and low pressure are low.

- Blockage inside

- Cleaning/replacement

Blockage in fins

Air quantity is small. (Filters may be clogged.)

- Blockage in fins

- Cleaning

Air quantity is small, and low pressure is low.

- Blockage in filter (Evaporator is not preforming inadequately.)

- Cleaning/replacement

Freezing

Action

65ZV-2 US 72-57 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Expansion valve (box type)

(Evaporator)

Expansion valve operation

Diaphragm Evaporator

Spring Temperature sensing rod Diaphragm

Temperature sensing rod Needle valve (To compressor) (From receiver)

Needle valve From receiver (High pressure)

Structural drawing of box type expansion valve

To compressor (Low pressure)

97ZV72049

97ZV72050

The expansion valve offers the following two functions.

The temperature sensing rod detects the temperature of the refrigerant, and transfers the detected temperature to the refrigerant gas chamber.

1. By injecting the liquid refrigerant at high temperature and high pressure which has gone through the receiver from a small hole, the expansion valve expands dramatically the liquid refrigerant into mist refrigerant at low temperature and low pressure. 2. Promptly in accordance with the vaporized status of the refrigerant inside the evaporator, the expansion valve adjusts the refrigerant quantity. In order to ensure that the evaporator offers its full performance, the liquid refrigerant should be kept in a state in which it deprives heat of the adjacent area and its evaporation is always completed at the exit of the evaporator. To realize this, the expansion valve automatically adjusts the refrigerant quantity in accordance with fluctuation of the temperature inside the cab (cooling load) and fluctuation of the rotation speed of the compressor. The expansion valve consists of a needle valve, a diaphragm and a temperature sensing rod. The temperature sensing rod detects the temperature of the refrigerant which has gone through the evaporator, and transfers the detected temperature to the refrigerant gas chamber located in the upper portion of the diaphragm chamber.

The gas pressure changes in accordance with the detected temperature, the temperature sensing rod directly connected to the diaphragm is moved, then the needle valve opening is adjusted. - When the temperature at the exit of the evaporator is low or when cooling load is small, following occurs. The gas pressure inside the diaphragm chamber becomes low, the volume decreases, the temperature sensing rod moves to the right, and the needle valve is closed. - When the temperature at the exit of the evaporator is high or when cooling load is great, following occurs. The gas pressure inside the diaphragm chamber becomes high, the volume increases, the temperature sensing rod moves to the left, the needle valve is opened, and more quantity of refrigerant is supplied to the evaporator.

65ZV-2 US 72-58 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) Troubleshooting the expansion valve Item

Symptom

Cause

Action

Blocked expansion Both high pressure and low pressure are low, valve or defective and air bubbles cannot be seen through sight adjustment (too closed) glass.

- Expansion valve

- Cleaning/adjustment or replacement

Defective adjustment (too open)

Low pressure is too high, and compressor head is cold.

- Expansion valve

- Adjustment or replacement

Freezing caused by moisture

Cooling is disabled during operation. Frosting is not detected in evaporator. Both high pressure and low pressure are low, and air bubbles cannot be seen through sight glass.

- Expansion valve

- Replace receiver tank, evacuate air, then charge gas again.

65ZV-2 US 72-59 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Heater radiator coil

Fin

Heater core

97ZV72051

The heater radiator utilizes the engine cooling water as the heat source. When going through the heater radiator, the air receives heat from the heater radiator fins and is warmed. The hot water inside the heater radiator is forcedly circulated by the engine water pump. Troubleshooting the heater radiator Item Water leak

Symptom Water leaks from heater core.

Cause - Joint portion of supply area - Cracks in heater core main body

Action - Repair/replacement

Blockage in circuit

Air inside cab does not become warm.

- Blockage inside heater radiator

- Replacement

Blockage in fins

Air quantity is small.

- Blockage in fins

- Cleaning

65ZV-2 US 72-60 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

5 4

3 2 1

Servo motor

2 3

4 6 7

97ZV72052

When a switch on the control panel is pressed, the power is applied from the control panel on the terminal (6) or (7) of the servomotor. (The rotating direction is determined by the terminal on which the power is applied.) A variable resistor is provided inside the servo motor. As the motor rotates, the resistance of this resistor changes accordingly. When the 5 V voltage is supplied from the control panel to this variable resistor, the control panel detects the variable resistor position based on the electric potential difference. When the variable resistor reaches the position specified by each switch, the power supplied to the motor is stopped. Note If the power is directly applied on terminals of the motor, the output shaft of the motor may be damaged or wire breakage may occur in the motor coil. Do not directly drive terminals of the motor. Troubleshooting the servo motor Item Motor is locked (disabled). Contact is contacting poorly.

Symptom

Cause

Action

- Servo motor does not rotate.

- Motor - Control unit

- Repair/replacement

- Indicator lamps of temperature setting switches do not light in accordance with preset pattern. - Servo motor does not stop in accordance with preset pattern.

- Fixed plate - Moving contact - Control unit

- Repair/replacement

65ZV-2 US 72-61 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Blower motor assembly

Blower motor assembly specifications

Fan

Blower motor

Voltage

DC 24 V

Number of rotations of motor

3,100 min-1

Power consumption

225 W (9.4 amps) ± 10%

Fan outer diameter

ø150 (5.9")

Note This unit can be bench tested with 24 V DC by using normal test methods. Determine if excessive amperage is required to turn it. It is controlled by the speed control (BLC) below. Air Air 97ZV72053

The blower motor assembly consists of a DC motor and a fan, and blows air. Troubleshooting the blower motor Item Blower motor operation is defective.

Symptom Air is not blown at all.

Cause - Blower motor - Control unit

Action - Repair/replacement

BLC (blower linear control)

85V2U72004

97ZV72054

This resistor changes over the air quantity of the blower motor. Troubleshooting the blower linear control Item

Symptom

Cause

Wire in BLC is broken.

Air quantity does not change.

- BLC - Control unit

Blower motor operation is defective.

Air is not blown at all.

- Blower motor - Control unit

Action - Replacement - Repair/replacement

65ZV-2 US 72-62 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

De-icing sensor (Thermistor (or thermal resistor))

Evaporator

Appearance of thermistor 8,000 7,000

Resistance ()

6,000

Thermistor

5,000

Heater radiator

4,000

97ZV72056

3,000 2,000 1,000 0

10 (14)

5 (23)

0 (32)

5 (41)

10 (50)

15 (59)

20 (68)

25 (77)

30 (86)

Temperature (ºC) (ºF) Characteristics curve between temperature 85V2U72005 and resistance of thermistor

The thermistor, a kind of semi-conductor, offers the characteristics as shown in the curve on the above. When the temperature becomes high, its resistance becomes small. When the temperature becomes low, its resistance becomes large.

The thermistor mounted on the blowoff port side of the evaporator detects the temperature of the air cooled by the evaporator, and transmits it as a signal to the control amplifier. If the air at the vent is 3ºC (37ºF) or less, the control amplifier turns off the compressor clutch relay. If the air at the blowoff port becomes 4ºC (39ºF) or more, the control amplifier turns on the compressor clutch relay again to restart cooling. Because the air temperature at the vent is detected and the compressor clutch relay is turned on and off accordingly, freezing of the evaporator is prevented.

Troubleshooting the thermistor Item

Symptom

Cable in thermistor is broken.

Compressor clutch does not work.

Thermistor is short-circuited.

Air not blowing.

*Note For temperature reference between ºC and ºF please see references below. Temp ºC

Temp ºF

-10ºC 0ºC 10ºC 20ºC 25ºC 30ºC

14ºF 32ºF 50ºF 68ºF 77ºF 86ºF

Cause - Thermistor

Action - Replacement

65ZV-2 US 72-63 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Water temperature sensor

Foot/defroster selection box

Air conditioner unit

Foot Def 97ZV72057

97ZV72059

This sensor detects the temperature of the engine cooling water flowing into the heater core, and feeds it back to the control panel.

This selection box changes over the vent positions between the foot side and the defroster side.

This sensor is installed on the rear side of the heater core, and can be taken out when being pulled out. Temperature

Resistance value

-30ºC (-22ºF)

91.4 k

25ºC (77ºF)

5 k

100ºC (212ºF)

0.321 

Inside air temperature sensor

97ZV72058

This sensor detects the air temperature inside the cab, and feeds it back to the control panel. This sensor is installed in the inside are suction port, and can be taken out when the clamp is removed. Temperature

Resistance value

0ºC (32ºF)

16.45 k

25ºC (77ºF)

5 k

When the vent mode selector switch (MODE) on the control panel is pressed, the servo motor in this selection box changes over the vent selection damper to the foot side or the defroster side by way of a link and lever.

65ZV-2 US 72-64 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Compressor and magnetic clutch

Compressor specifications

Compressor Piston

Discharge valve

3 10 5

Suction valve Diagonal plate

Suction valve

Suction/compression action

9 11 97ZV72060

1. Compressor 2. Magnetic clutch 3. Rotor 4. Stator 5. Hub 6. Pulley

7. Coil 8. Bearing 9. Shaft 10. Dust proof cover 11. Pressure relief valve

The compressor is driven by the V belt from the engine by way of the magnetic clutch. The compressor draws in and compresses the gaseous refrigerant at low temperature and low pressure which deprived heat of the air inside the cab in the evaporator and was vaporized to make the gaseous refrigerant be at high temperature and high pressure, then feeds it to the circuit on the high pressure side again. Five pairs of pistons (with ten cylinders) reciprocate in the same direction with the shaft in accordance with rotations of the shaft. Accordingly, when one piston of a pair is in the compression stroke, the other one is in the vacuum stroke. The compressor is lubricated by the compressor oil contained in the gaseous refrigerant and the oil splashed by the diagonal plate. Accordingly, if the refrigerant quantity decreases, the compressor will seize from oil starvation. To prevent seizure, a pressure switch is provided in the circuit so that the power supplied to the magnetic clutch is shut down and the compressor is protected when the refrigerant quantity decreases.

97ZV72061

Model

10S150

Cylinder diameter

ø32 (1.26")

Stroke

20.8 mm (0.82")

Number of cylinders

Cylinder capacity

167.3 cm3 (10.21"3)

Maximum allowable number of rotations

6,000 min-1

Lubricating oil

ND-OIL8

Lubricating oil quantity

180 cm3 (11"3) [6 oz]

65ZV-2 US 72-65 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Magnetic clutch

Magnet clutch specifications

Pulled force Stator Switch Iron piece (rotor)

Power supply Magnetic force N

Principle of magnetic clutch

97ZV72062

The magnetic clutch controls mechanical connection between the engine and the compressor. When the engine is rotating and the air conditioner ON/OFF switch is ON, if the temperature inside the cab reaches or exceeds the temperature set by the temperature setting switches, the magnetic clutch stops or drives the compressor.

Suction face

Pulley Stator coil

Hub

Rotor

Stator Ball bearing

Magnet clutch 97ZV72063

The hub of the magnetic clutch is fitted onto the shaft of the compressor. While the compressor is not driven, the hub is separated from the rotor and only the pulley is rotating. When the air conditioner switch is set to ON, the current flows in the stator coil, the stator works as a magnet and engages the hub, then the compressor rotates together with the pulley. When the current applied on the stator coil is set to OFF, the hub is not immediately separated but rotates together with the pulley because the pulley has residual magnetism. Accordingly, clearance is provided between the hub and pulley so that they are not in close contact with each other during disengagement. This clearance is called air gap.

Model

L50T

Voltage

DC 24 V

Power consumption

40 W (1.67 amps)

Drive belt

V-ribbed belt (six ribs)

Air gap

0.5±0.15 mm (0.020" ± 0.006")

65ZV-2 US 72-66 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) Troubleshooting the compressor and magnetic clutch Item

Symptom

Suction or exhaust valve is damaged. *

- Compressor temperature is abnormally high. - High pressure is abnormally low, and low pressure is abnormally high. - Air bubbles cannot be seen through sight glass.

Cause

Action

- Suction or exhaust valve

- Repair/replacement

Clutch draw voltage is low.

- Stator coil

- Replacement

Power is not supplied to stator coil.

- Wiring on main body - Control amplifier - Pressure switch

- Repair - Replacement - Replacement

- Magnetic clutch

- Replacement

Compressor main body is defective (seized, etc.).

- Shaft, piston

- Repair/replacement

Clutch bearing is damaged.

- Clutch bearing

- Replacement

- Magnetic clutch

- Replacement

V belt is slack.

- V belt

- Adjustment/replacement

Compressor main body is defective.

- Internal compressor trouble

- Repair/replacement

- V belt

- Adjustment/replacement

- Abnormal sounds are made while clutch is turned on.

Gap between hub and rotor is large.

Contact or slippage caused by too small gap between hub and rotor.

V belt is slack.

- Compressor does not rotate. (Air in cab does not become cool enough.)

- Abnormal sounds are made while clutch is turned off.

- Abnormal sounds are made while clutch is turned on.

* This can be the result of "liquid charging". Do not liquid charge as a compressor cannot compress liquid; this will damage it.

65ZV-2 US 72-67 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Condenser unit

Condenser fan motor The condenser fan motor used to cool down the condenser is mounted on the condenser together with a fan shroud.

Condenser Blower assembly Resistor Cover

Fan motor 95V2U72002

Each condenser unit consists of a condenser, a condenser fan motor and a resistor. Two condenser units are arranged in series with the piping. The condenser units cool down the gaseous refrigerant at high temperature and high pressure sent from the compressor, and change it into liquid refrigerant.

Condenser The condenser consisting of tubes and fins cools down the gaseous refrigerant at high temperature and high pressure (70ºC, 1,618 kPa (16.5 kgf/cm2)) (158ºF (235 psi)) sent from the compressor, and change it into liquid refrigerant during passing tubes.

Condenser specifications Voltage

DC 24 V

Power consumption

80 W (3.4 amps) x 10%

Air quantity

1,750±10 m3/Hr (61,800"3/Hr)

Number of rotations of motor

2,200 min-1 (rpm)

65ZV-2 US 72-68 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Resistor The resistor controls rotation of the condenser fan motor in two steps in accordance with a command given by the fan control pressure switch (medium pressure switch). Resistor specifications 4.0 

Resistance

Troubleshooting the condenser unit Item

Symptom

Heat radiation quantity is insufficient due to blockage*. Both high pressure and low pressure are abnormally high, and air does not become Rotation of condenser fan cool enough. motor is defective. High pressure is abnormally high, low pressure is abnormally low, and air does not Blockage / condenser airflow become cool enough. Air bubbles can be seen through sight glass. Gas leak

Both high pressure and low pressure are abnormally low, and air bubbles can be seen through sight glass.

Cause

Action

- Blockage or crushed fins

- Clean or replace condenser

- Fan motor

- Repair or replace motor

- Internal to condenser fins

- Clean or replace condenser

- Leaks at joints - Cracks in main body

- Tightening - Repair or replacement

* It is important to check the fan blades also as these can become bent or packed with dirt, making them ineffective.

65ZV-2 US 72-69 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Receiver dryer

Desiccant

Refrigerant inlet Refrigerant outlet

Desiccant

If moisture is present inside the cooling circuit, the compressor valve and oil may deteriorate, metal parts within the circuit may corrode, or moisture may be frozen inside expansion valve which may clog the circuit. To prevent such failure, synthetic zeolite (drying agent) is positioned inside the air conditioner and acts as a desiccant suitable to the circuit so that it absorbs moisture entering the circuit during installation or refrigerant charging. When the expansion valve is often frozen by moisture (icing), the desiccating agent does not have enough absorption ability. When this happens, the receiver must be replaced.

Strainer

Desiccant specifications

Receiver tube

Receiver tank

97ZV72065

The receiver dryer consists of a receiver tank, desiccant, strainers, and a receiver tube.

Receiver tank In the air conditioner, the number of rotations of the compressor changes and the proper refrigerant quantity in the cooling circuit fluctuates in accordance with fluctuation of the number of revolution of the engine. The receiver tank receives such fluctuation. When the cooling circuit does not require much refrigerant, the receiver stores temporarily excess refrigerant. When the cooling circuit requires much refrigerant, the receiver tank supplies refrigerant from its receiver tube to the circuit. In addition, the receiver tank stores a reserve of refrigerant in order to take balance of charging of the refrigerant and respond to any minute leaks of the refrigerant caused by permeation through rubber hoses.

Capacity

550 cm3

Desiccating agent

Synthetic zeolite

Desiccating agent capacity

290 g

IMPORTANT If parts of the cooling circuit are removed and left for a long time for repair or another reason, the desiccant absorbs moisture contained in the air and loses its absorption performance, and the receiver dryer should be replaced. To prevent this, after parts are removed, all openings should be plugged.

65ZV-2 US 72-70 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Strainers If dusts enter the circuit, the expansion valve may be clogged, the compressor may be damaged, and the cooling function may be deteriorated. Strainers are provided to prevent dusts from flowing with in the refrigerant. The strainers cannot be cleaned. When they are considerably clogged (in this case, the high pressure increases and the low pressure decreases), the entire receiver dryer should be replaced. Troubleshooting the receiver tank Item

Symptom

Cause

Action

Icing

- At first, air in cab will cool down, but after a short time no longer will cool properly.

- Desiccating agent in receiver

- Replacement of receiver dryer

Blockage in strainers

- High pressure is excessively high, low pressure is excessively low, and air does not become cool enough*.

- Blockage in strainers

- Replacement of receiver dryer

*A means to test this is to check the temperature between the inlet and outlet of receiver dryer. If it drops more than it should the dryer is plugging and should be replaced.

65ZV-2 US 72-71 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Sight glass

Pressure switches

Sight glass

Terminal

Receiver joint

Contact area

Receiver dryer

97ZV72066

97ZV72067

This sight glass is installed on the receiver joint located on the top of the receiver dryer. Only through this sight glass, the refrigerant quantity inside the circuit can be visually checked.

The pressure switch detects the pressure on the high pressure side of the cooling circuit, and stops the compressor when detecting any abnormality so that damage of the equipment in the cooling circuit can be prevented.

WARNING Possible freezing of eye tissue. Always wear protective eyewear when doing a visual inspection.

There are three types of pressure switches, high pressure type, medium pressure type and low pressure type, which function as shown in the table below.

65ZV-2 US 72-72 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Switch

Switching pressure kPa (kgf/cm2) (psi)

Function

Switch operation confirmation method

Causes of abnormal pressure

Pressure switch coupler

High pressure switch

When pressure between compressor and expansion valve becomes abnormally high, this switch shuts down power supplied to compressor magnetic clutch to protect circuit.

2,550 (26) (370)

3,136 (32) (455)

D B

OFF

Heat radiation of condenser is insufficient due to clogging in condenser or defective rotation of condenser fan*. *A damaged fan blade would produce a similar symptom.

Check conductivity between A and B.

Medium pressure switch

When detecting fluctuation of pressure between compressor and expansion valve, this switch gives a signal to control amplifier about whether to rotate condenser fan motor at low speed or high speed. While this switch is ON, fan motor rotates at high speed. While this switch is OFF, fan motor rotates at low speed.

Low pressure switch

When pressure between compressor and expansion valve becomes abnormally low due to refrigerant leak, this switch shuts down power supplied to compressor magnetic clutch to prevent seizure of compressor caused by insufficient compressor oil which decreased together with refrigerant.

1,519 (15.5) (220) ON

Check conductivity between C and D in pressure switch coupler shown above.

OFF 1,225 (12.5) (178)

226 (2.3) (33) ON

Check conductivity between A and B Refrigerant leak from a part in pressure switch coupler shown of circuit. above.

OFF 196 (2.0) (28)

Troubleshooting the pressure switch Item Insufficient cooling

Symptom

Cause

- Condenser fan motor does not change its speed (to high speed).

Action

- Medium pressure switch

- Replacement

- High or low pressure switch*

- Replacement

Gas leak

- Even when abnormal high pressure (3,136 kPa (32 kgf/cm ) (455 psi)) occurs, compressor does not turn off. - Even when gas (refrigerant) has run short, compressor does not turn off.

*If abnormally high pressure occurs while the high pressure switch is non-functioning, the equipment in the cooling circuit may be damaged. The pressure relief valve releases the refrigerant to the atmosphere in order to prevent equipment or personnel damage.

65ZV-2 US 72-73 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Pressure relief valve

Flow rate (L/min) 113

Gas discharge route while valve is operating 97ZV72071

This valve mounted on the high pressure side of the compressor service valve releases the refrigerant to the atmosphere when abnormal high pressure occurs.

Pressure 28.1 2,756 400

35.0 3,430 500

42.4 4,158 600

(kgf/cm2 ) (kPa) (psi)

Characteristics drawing of relief valve operation 97ZV72069a

Pressure relief valve 97ZV72070

IMPORTANT When the refrigerant quantity inside the cooling circuit is correct, the pressure switch always remains ON even if the compressor is stopped because the refrigerant pressure is approximately 588 kPa (6.0 kgf/cm2) (85 psi) as far as the outside air temperature is around 25ºC (77ºF). When the outside air temperature becomes 0ºC (32ºF) or less, the pressure switch for low pressure detection turns off even if the refrigerant quantity is proper because the refrigerant pressure becomes 196 kPa (2.0 kgf/cm2) (28 psi) or less. As a result, the compressor does not work. It means that the pressure switch for low pressure detection functions also as a thermostat which detects the outside air temperature.

65ZV-2 US 72-74 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Relay A

Relay B

(Condenser fan, condenser fan high, compressor clutch)

(Evaporator fan motor, low/high)

97ZV72072

Relay A specifications

97ZV72099

Relay B specifications

Rated voltage

DC 24 V

Rated voltage

DC 24 V

Rated current

16 A

Rated current

11 A

Rated coil current

0.1 A

Rated coil current

0.075 A

Troubleshooting the relay Item

Coil wire is broken. Contact is melted down.

Symptom

Cause

- Blower motor does not rotate at all. - Blower motor remains rotating.

- Blower motor main relay

- Blower motor does not rotate at high speed. - Blower motor remains rotating at high speed.

- Blower motor Hi relay

- Blower motor does not rotate at medium speed Me2. - Blower motor speed does not change from Me2 to Me1.

- Blower motor Me2 relay

- Blower motor does not rotate at medium speed Me1. - Blower motor speed does not change from Me1 to low speed.

- Blower motor Me1 relay

- Both condenser fans do not rotate. - Both condenser fans remain rotating.

- Condenser fan relay

- When condenser fan is at high pressure, it does not rotate at high speed. - When condenser fan is at low pressure, it remains rotating at high speed.

- Condenser fan relay 1

- Compressor magnetic clutch does not turn on. - Compressor magnetic clutch remains ON.

- Compressor clutch relay

Action

- Replacement

65ZV-2 US 72-75 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Refrigerant hose

WARNING Burst hazard These hoses operate at high pressure for HVAC systems and must not be replaced with substandard hoses.

Outer layer Reinforcing layer

Use only OEM replacement hoses or hoses of the same rating as OEM replacement hoses. Mouth ring Inner layer Intermediate layer 97ZV72073

White line and "R134a" indication

97ZV72074

As shown in the figure on the above, the refrigerant hose consists of the outer layer, the reinforcing layer, the intermediate layer and the inner layer, and the mouth ring is crimped. Region

Material

Outer layer

Ethylene propylene rubber

Reinforcing layer

Polyester

Intermediate layer

Chlorinated butyl rubber

Inner layer

Nylon

The mouth ring of this hose is changed and the symbol "R134a" is indicated on this hose as shown in the figure on the right.

IMPORTANT Never use any other hose or any other refrigerant. Otherwise, refrigerant may leak.

65ZV-2 US 72-76 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Charge of refrigerant WARNING WARNING Serious accidents may occur in the refrigerant charging work. Observe the following contents. - Only trained or experienced specialists having sufficient knowledge on the contents of the work should be allowed to perform the refrigerant charging work. - If the refrigerant comes into contact with your eyes, you may lose your eyesight. Make sure to wear protective goggles. - The refrigerant in the liquid status is at low temperature (approximately -30ºC (-22ºF)). If it splashes on your skin, you may suffer from frostbite. Pay close attention when handling it. - If the refrigerant (Refrigerant R134a) touches a hot object (approximately +400ºC or more), it decomposes and generates harmful substances. Never release the refrigerant in a room where ventilation is bad and there is a hot object or a fire (such as in the presence of a stove). - In order to protect the environment, do not release the gaseous refrigerant to the atmosphere.

Serious accidents may occur during storage and transportation of a service can. Observe the following contents. - A service can accommodates high pressure gas in the saturated liquid status. If the temperature rises, the pressure may increase drastically and the can may burst. Keep the temperature of the service can at 40ºC (104ºF) or less. Make sure to keep the can away from hot objects or fire. - During storage, make sure to avoid direct sunlight, and store the can in a dark and cool place. - Inside the closed cab (including trunk), the air temperature may rise considerably due to solar heat, etc., and may become dangerously temperature even in winter if the closed cab is exposed to direct sunlight. Never put the can inside the cab. - If the service can suffer from flaws, dents and deformations, its strength deteriorates. Never hit or drop it. And never throw or drop a package of cans while loading or unloading it. - Keep the can away from the reach of children.

IMPORTANT CAUTION Serious accidents may occur during the refrigerant charging work. Observe the following contents. - When warming a service can to charge the refrigerant, make sure to open the low pressure valves of the service can and the gauge manifold, then warm it with hot water of 40ºC (104ºF) or less (temperature at which you feel warm when putting your hand into it). Never warm the can with boiling water or overheat it with open fire. If the can is treated in such a way, it may burst. - When charging the refrigerant after having started the engine, never open the high pressure (Hi) valve. If it is opened, the high pressure gas may flow in the reverse direction, and the service can and the hose may burst.

- It is prohibited by law to reuse service cans. Never reuse them. - Pay close attention so that air and dusts do not enter into the cooling circuit. - Never charge the refrigerant excessively. - The air conditioner is so designed as to be used with Refrigerant R134a. Never charge any other refrigerant such as Freon R12. - If the compressor oil (ND-OIL 8) adheres to the painting face or the resin area, the painting may peel off or the resin may be damaged. If so, wipe it off soon. - Tighten the piping at the specified torque.

65ZV-2 US 72-77 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Work procedure

Charging procedure

The refrigerant charging process is mainly divided into "refrigerant evacuation procedure" and "gas charging procedure" as shown below.

1. Charge the system with the required amount of gas by weight, and check for leaks by letting the HVAC system sit static and permit pressure to equalize. 2. Check the system pressure in comparison to the ambient temperature. If acceptable, go to next step (3). 3. Turn on the engine, run at 1,200~1,500 rpm. 4. Turn on the HVAC air condition system, making sure that the heat is off and A/C is set with fan on high. 5. Let the HVAC system run on coldest setting until all parts are cold saturated; this should take about 30 minutes or more. 6. Check the temperature that is coming from the vents of the HVAC system inside the cab. Check the performance in the operating pressure and temperature chart. 7. Either remove or install more refrigerant depending upon the findings.

Refrigerant evacuation procedure The "refrigerant evacuation process"* eliminates moisture present inside the cooling circuit. If the moisture remains inside the circuit, it may cause varied problems even if its quantity is extremely small: The moisture may freeze inside the expansion valve during operation, and may block the circuit or generate oxidation. To prevent such problems, the refrigerant containing air inside the cooling circuit should be evacuated, and the moisture inside the circuit should be boiled and evaporated so that all moisture is eliminated before pure refrigerant is recharged into the circuit. *May be referred to as "air evacuation procedure" since it contains air which also contains water that can cause system damage as noted.

Gas charging procedure The "gas charging procedure" charges the refrigerant as gas into the circuit while in a vacuum state. The gas charging process not only affects the cooling ability of the air conditioner but also affects the system component life.* If the refrigerant is charged too quickly or in a liquid state, pressure inside the circuit may become extremely high and the cooling ability may deteriorate. If the refrigerant charging volume is too low, the lubricating oil for the compressor may not circulate smoothly and compressor pistons may seize and lock up the compressor. Because the gas charging process involves high pressure gas, it is extremely dangerous if it is not done correctly. Observe the work procedure shown below and the cautions, and charge the refrigerant correctly. *Note Liquid charging destroys a compressor. Never permit entry of liquid refrigerant.

Observe the work procedure and cautions shown below, and charge the refrigerant correctly. The system should operate within about 5% of the parameters. Be sure that the condenser is clear, evaporator is clean and the fans are all working as they should with good airflow in the system. Note If the inside of the cab become cold during the charging process, the compressor magnetic clutch turns off and system charging is disabled. When charging, completely open the cab doors. This will keep the system from turning off and on.

65ZV-2 US 72-78 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Charging procedure chart

Start evacuation. 20~30 min Refrigerant evacuation process

Stop evacuation.

-750 mmHg (-30" Hg) or less If too little vacuum, repair leaking connection*

Leave system untouched for 5 min. Check pressure.

*It is possible that system may need pressurized and tested for leaks.

Stop when gage indicates excessive pressure (air entry)

When gage indicates a normal value Charge refrigerant gas.

Check for gas leak. Gas charging process

Charge gaseous refrigerant until gauge pressure reaches 98 kPa (1 kgf/cm2) (14 psi). Check for leaks.

Note A full charge should be about 2±0.1 lbs (900±50 g) of refrigerant.

Charge refrigerant.

Check for gas leak.

As a general guideline, with engine off and HVAC system static, the pressure in the system should be about 85 psi (588 kPa) (6.0 kgf/cm2) with the pressure has equalized between the low and high pressure side.

Performance test 95ZVE72042

65ZV-2 US 72-79 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Refrigerant charging tools

Charging hose and quick connectors

Recovery and recycling unit

Gauge manifold*

Low pressure charging hose (blue) 95ZV72024

It is against Federal Regulations* in the United States to release refrigerant to atmosphere. A recovery and recycling unit must be used to capture the refrigerant so as not to release it into the atmosphere. *Refer to section 609 of the clean air act at www.epa.gov.

It is used for the following; 1. Recover the refrigerant. 2. Filter the refrigerant. 3. Measure the refrigerant weight. 4. Remove trapped non compressible gases (air). 5. Measure the refrigerant to install in system by weight. 6. Measure the pressure of the refrigerant in system. 7. Measure ambient temperature. 8. View bubbles in system if there are any. Read and understand the Operation Manual for the recovery and recycling machine.

IMPORTANT Only use a vacuum pump if the system is already open to atmosphere and refrigerant has completely left the system.

High pressure charging hose (red)

Quick connector (Lo)

Center charging hose (green or yellow) Quick connector (Hi)

97ZV72077

These different colored hoses are used to evacuate the air and charge the gas. (The colors may be different depending on the manufacturer.) Red hose Connects the high pressure valve of the gauge manifold and the high pressure charging valve (with "H" mark on its cap) of compressor outlet hose. Blue hose Connects the low pressure valve of the gauge manifold and the low pressure charging valve (with "L" mark on its cap) of the compressor inlet hose. Green or yellow hose Connects the center valve of the gauge manifold and the vacuum pump (or the service can valve). *Gauge manifold may be used with vacuum pump or recovery unit.

65ZV-2 US 72-80 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Gauge manifold

Leak detector

Many recovery and recycling units are equipped with a gauge manifold, which is very similar to the gauge manifolds that were used for earlier application refrigerant handling systems. Typically, the low pressure side hose color is blue, the charging hose color is yellow (may be light green), and the high pressure side hose color is red. These are generally integrated into the recovery and recycling unit. 85V2U72007

Low pressure gauge

High pressure gauge

A leak detector find areas where refrigerant traces are leaking and sounds an alarm to alert the technician of areas of leakage. Gauge manifold

Low pressure valve Low pressure charging hose Center valve mounting nipple Center charging hose mounting nipple

High pressure valve High pressure charging hose mounting nipple 97ZV72078

It is used to evacuate the air and charge the gas, and equipped with a high pressure gauge, a low pressure gage, plus valves and hose mounting nipples as shown in the figure on the above. Some gauge manifolds are equipped with sight glasses. These are used to check for bubbles in the refrigerant. Excessive flow of bubbles may indicate: 1. Low pressure. 2. Leak to atmosphere (air ingestion) when in vacuum. 3. Boiling action, perhaps due to pressure changes.

65ZV-2 US 72-81 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Cautions on handling of quick connector and charging valve When discharging the refrigerant, use a quick connector.

Precautions

Quick connector

1. Connecting the quick connector.

Screwdriver, etc. Sleeve

"Click" sound (OK) Valve pin

(A) Spring

Charging valve

97ZV72082

97ZV72080

IMPORTANT Slide the sleeve upward, push the quick connector against the charging valve, press and hold securely part (A) until a click is heard, then slide the sleeve downward.

IMPORTANT - Push quick connector against charging valve vertically. - If refrigerant remains inside the charging hose, the quick connector may not be easily connected. 2. Disconnecting the quick connector

Sleeve

"Click" sound (OK)

(A)

(B)

97ZV72081

While pressing and holding the part (A) of the quick connector, slide sleeve upward to disconnect quick connector.

If you push the valve pin with a considerable force [294 kPa (3 kgf/cm2) (43 psi)] with a screwdriver, etc., the spring may come off and the refrigerant may leak. Never do this.

65ZV-2 US 72-82 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Refrigerant charging procedure

Valve setting

Air evacuation work

Lo Hi Closed Closed High pressure valve

WARNING If hoses are connected incorrectly, serious accidents may occur. Observe the following. - Never confuse connection of hose to the high pressure side and the low pressure side of the gauge manifold.

Low pressure valve

(red) (blue) (green)

(Hi)

Recovery and recycling unit (Lo)

Charging valve on high pressure side (located on receiver dryer) Vacuum pump shown Compressor (stopped) A refrigerant recycle and recovery unit may be used. 95ZVE72045

95ZV72024

With system "OFF"; (a) Close both the high pressure (Hi) valve and the low pressure (Lo) valve of the gauge manifold. (b) Connect the charging hose.

Red hose To be connected between the high pressure (Hi) valve of the gauge manifold and the high pressure charging valve.

*Refer to section 609 of the clean air act at www.epa.gov.

1. Connecting the gauge manifold

CAUTION Close both low and high pressure valve, as seen in "a" below.

Blue hose To be connected between the low pressure (Lo) valve of the gauge manifold and the low pressure charging valve of the compressor. Yellow or green hose To be connected between center valve of gauge manifold and recovery unit (equipped with vacuum pump).

IMPORTANT Connect quick connectors to both the high pressure and low pressure sides before starting air evacuation. The check valve of a quick connector cannot hold vacuum status. If a side of quick connector is not connected, a vacuum condition cannot take place.

65ZV-2 US 72-83 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) 2b. Evacuating the system with a recycling and recovery unit.

2a. Evacuating the system with a vacuum pump When pulling a vacuum with a vacuum pump on a system that has been open due to replacing major components.

Valve setting

After air evacuation Valve setting Lo Hi Lo Hi for 30 minutes OpenedOpened Closed Closed High pressure valve

Low pressure valve 95ZV72024

(red) (blue) (green)

(Hi) (Lo) Charging valve on high pressure side Vacuum pump (operating) Compressor (stopped)

(stopped) 95ZVE72046

(a) Open both the high pressure (High) valve and the low pressure (Low) valve of the gauge manifold. (b) Turn on the switch of the vacuum pump, and evacuate until the degree of vacuum becomes -750 mm Hg (-30" Hg) for about 20~30 minutes. (c) After finishing evacuation, close both the high pressure valve and the low pressure valve of the gauge manifold. Then, turn off the switch of the vacuum pump.

IMPORTANT If you stop the vacuum pump before closing each valve of the gauge manifold, refrigerant from vacuum unit and tank is released to the atmosphere. It is important to first close both high and low side valves.

Each manufacture of recycling and recovery units provide operating instructions for their units. Read, understand and closely follow operating instructions as provided.

65ZV-2 US 72-84 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) 3. Checking for leaks after vacuum has been drawn Valve setting

Leave for 10 minutes or more as per EPA regulations Lo Hi Pointer of low Closed Closed pressure gauge moves toward "0". Low pressure gauge 0

Moves toward "0".

Tighten connection areas of piping. 97ZV72085

After a vacuum has been pulled on system;

Refrigerant charging process This section describes a static charging procedure with the engine in "OFF" and compressor not turning. Do not run engine until high and low pressures are equal so that no damage is done to the compressor. The illustrations below show use of a gauge manifold assembly. This is not the preferred method in the USA due to EPA regulations against purging refrigerant to atmosphere. Use of a recovery and recycle unit is best. Carefully follow instructions with recovery unit. Valve setting Lo Hi Closed Closed

Leave the circuit for 5 minutes or more with H and L valves of gauge manifold closed. Then, make sure that the needle of each gauge does not move. If the needle of the gauge moves toward "0", a leak has occurred somewhere in the circuit. Tighten the connection areas of the piping, evacuate the system again, then make sure that there is no leaks.

Open the service canister valve. Blue (low)

Red (high) Service Charging hose R134a canister

(green or yellow)

97ZV72086

IMPORTANT Make sure to tighten the connection areas of the piping at a specified tightening torque. For the tightening torque, refer to the volume "Maintenance Standard".

IMPORTANT Never purge or vent refrigerant to atmosphere. (EPA)

65ZV-2 US 72-85 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Valve setting Lo Hi OpenedOpened

1. Charging the refrigerant from the high pressure side with the engine in the "OFF“ position.

Valve setting

After 1~1.5 service cans are charged

Lo Hi Closed Closed

High pressure valve

(a) After evacuation, disconnect the charging hose (green or yellow) of gauge manifold from vacuum pump, and connect it to the service canister. (b) Purging air from lines

Low pressure valve (red)

(blue)

(green)

(Hi)

Open the service canister valve very slightly with low and high pressure manifold valves closed. Open both high and low side valves so that lines are charged. Connect lines to HVAC system. A small amount of trapped air will escape from the lines, as air is discharged by the refrigerant pressure. EPA says that release of this tiny bit of air that is very small is ok.

(Lo) Charging valve on high pressure side

Compressor (stopped)

Service can valve (opened charge R134a closed) 95ZVE72052

WARNING If the refrigerant were changed from the high pressure side, the refrigerant would flow in reverse direction and the can and the hose may be burst if you start the engine and operate the compressor. Never start the engine in this condition.

IMPORTANT If you charge refrigerant with refrigerant canister placed upside down liquid will exit canister, refrigerant is sucked into the compressor in a liquid state. This will damage the compressor. Charge only with refrigerant gas.

(c) WITH ENGINE "OFF"; Open tank canister valve and charge the gaseous refrigerant until gauge pressure read 98 kPa (1 kgf/cm2) (14 psi). (This should take about one to one and half one lb service cans. If using scale, add one to one and a half lbs.) (d) After charging, close the low and high pressure valves of the gauge manifold and the service can valve. 2. Check for gas leak with a leak detector Check for gas leak in the circuit using a leak tester, etc. If a leak is detected, repair leak as required. If located at connections, tighten the connection area.

IMPORTANT Make sure to tighten the connection areas of the piping at a specified tightening torque. For the tightening torque, refer to the volume "Maintenance Standard". Do not overtighten or it will worsen.

65ZV-2 US 72-86 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) 3. Charging the refrigerant - low pressure side - e/g "ON". Valve setting Lo Hi Opened Closed

Charge the refrigerant until air bubbles seen through the sight glass disappear.

(c) Start the engine, and increase the number of rotations to approximately 1,500 min-1(rpm). (d) On the control panel, set the fan speed to high and set the air flow volume to maximum cold, and set the vent port temperature switches to the coldest status.

Valve setting Lo Hi Closed Closed

High pressure valve

Low pressure valve

(e) Open the low pressure valve of the gauge manifold and service canister valve to charge the refrigerant. When air bubbles seen through the sight glass of the receiver dryer disappear, charge the refrigerant further more by 150~250 g.

(red)

(blue)

(green)

IMPORTANT (Hi)

(Lo) Charging valve on high pressure side

Compressor (On-load)

Service can valve (opened charge R134a closed) 95ZVE72052

When replacing service canister while charging refrigerant, connect the line as described earlier so as to not have air in the line. (f)

After charging, close the low pressure valve of the gage manifold and the service can valve. Then, stop the engine. Refrigerant quantity to be charged (guideline) 900±50 g (2.0±0.1 lb)

Refrigerant quantity

Proper

Gas bubbles are few. (When the number of rpm’s of the engine is gradually increased from the idle status to 1,500 min-1, gas bubbles disappear.)

Too much

Gas bubbles are not seen in the flow at all. System is over-pressurized. (In this case, both the high pressure and the low pressure are high, and the cooling ability is deteriorated.)

Insufficient

Many gas bubbles are seen in the flow. (Gas bubbles visibly seen constantly.)

Sight glass

Receiver joint

Receiver dryer

97ZV72066

(a) Make sure that the high and low pressure valves of the gauge manifold and service canister valve are closed. (b) If the inside of the cab becomes cold during the charging process, the compressor magnetic clutch turns off and system charging is disabled. When charging, completely open the cab doors. This will keep the system from turning off and on.

Sight glass situation

65ZV-2 US 72-87 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) 4. Guidelines to determine quantities of refrigerant charge

5. Disconnecting the gauge manifold

Use the following table to determine the refrigerant charge quantity. Sleeve Item

Criteria

Doors

Completely open

Temperature control switches

Maximum cooling

Blower speed

High

Inside/outside air selection

Inside air

"Click" sound (OK)

(A)

(B)

-1

Number of rotations of engine

1,500 min

Air conditioner switch

Pressure on high pressure side

1,862 kPa (19 kgf/cm2) (270 psi) or less

IMPORTANT - If outside air temperature is high (40ºC/104ºF or more) or if the pressure on the high pressure side is 1,862 kPa (19 kgf/cm2) (270 psi) or more when the judgement condition above is set, perform the following so that the pressure becomes 1,862 kPa (19 kgf/cm2) (270 psi) or less, then check the refrigerant quantity. - Close the doors completely, and set the blower fan to the low speed (by pressing the Lo switch). - Use a shaded area or a place indoors away from sunlight. - If you turn on the air conditioner while the refrigerant quantity is extremely low, lubricant in the compressor may be insufficient and a failure such as seizure of the compressor may occur. Never do this. - If the refrigerant quantity is over charged, cooling may be insufficient or the pressure inside the circuit may become abnormally high (which is dangerous). Never do this.

97ZV72081

After inspecting the refrigerant charge, disconnect the charging hose from the high and low pressure charging valves using the following procedure. (a) While pressing and holding part (A) of the quick connector, slide sleeve upward and disconnect the quick connector. (b) Attach a cap to each of the high and low pressure charging valves.

65ZV-2 US 72-88 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Troubleshooting using the gauge manifold Normal status

<Low pressure side> 215~275 kPa (2.2~2.8 kgf/cm2) (31~40 psi)

Condition After warming up the engine, check the pressure under the following condition. - Doors Completely open

<High pressure side> 1,470~1,765 kPa (15~18 kgf/cm2) (213~255 psi)

- Inside/outside air selection Inside air - Number of rotations of engine 1,500 min-1 - Temperature at suction port of air conditioner 30~35ºC (86~95ºF) - Blower speed High - Temperature control switches Maximum cooling

97ZV72091

Pressure values indicated by gauges in the normal status A/C suction port temperature 20~25ºC (68~77ºF) 25~30ºC (77~86ºF) 30~35ºC (86~95ºF) 35~40ºC (95~104ºF)

Pressure

Pressure value by gauge

High pressure side

1,000~1,215 kPa

Low pressure side

127~167 kPa

High pressure side

1,215~1,470 kPa

Low pressure side

167~215 kPa

High pressure side

1,470~1,784 kPa

Low pressure side

215~275 kPa

High pressure side

1,784~2,146 kPa

Low pressure side

275~353 kPa

(10.2~12.4 kgf/cm2) (145~176 psi) (1.3~1.7 kgf/cm2)

(18~24 psi)

(12.4~15.0 kgf/cm2) (176~213 psi) (1.7~2.2 kgf/cm2)

(24~31 psi)

(15.0~18.2 kgf/cm2) (213~258 psi) (2.2~2.8 kgf/cm2)

(31~40 psi)

(18.2~21.9 kgf/cm2) (258~310 psi) (2.8~3.6 kgf/cm2)

(40~51 psi)

65ZV-2 US 72-89 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

When the refrigerant charge quantity is insufficient <Low pressure side> 49~98 kPa (0.5~1.0 kgf/cm2) (7~14 psi)

<High pressure side> 686~981 kPa (7~10 kgf/cm2) (100~144 psi)

When the refrigerant does not circulate (due to clogging in the cooling circuit) <Low pressure side> Negative value

<High pressure side> 490~588 kPa (5~6 kgf/cm2) (71~85 psi)

97ZV72092

Symptom

Cause

- Pressure is low on both low and high pressure sides.

- Refrigerant quantity is insufficient.

- Gas bubbles go through sight glass continuously.

- Gas is leaking.

- Temperature of blown air is not cold.

Inspection/action point - Find and repair leaks. - Repair leak. Add refrigerant. - If pressure indicated by gage is around "0", detect and repair leaks, vacuum system and recharge.

97ZV72093

Symptom

Cause

Inspection/action point

- If cooling circuit is completely blocked, needle on low pressure side indicates a vacuum immediately.

Clogging in cooling circuit

- Inspect receiver dryer, expansion valve, etc. (Temperature is different between IN and OUT of failing part.)

- If cooling circuit is partially blocked, needle on low pressure side slowly indicates a vacuum.

- After finishing work, evacuate system and recharge.

65ZV-2 US 72-90 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

When the moisture has entered into the cooling circuit. <Low pressure side> Abnormal status Vacuum

<Low pressure side> 392~588 kPa (4~6 kgf/cm2) (57~85 psi)

<High pressure side> 686~981 kPa (7~10 kgf/cm2) (100~144 psi)

Normal status 215~275 kPa (2.2~2.8 kgf/cm2) (31~40 psi)

When the compression in compressor is defective. <High pressure side> 686~981 kPa (7~10 kgf/cm2) (100~144 psi)

1,470~1,765 kPa (15~18 kgf/cm2) (213~255 psi)

97ZV72095

97ZV72094

Symptom

Cause

Inspection/action point

- Air conditioner operates normally for a while after startup, but pressure on low pressure side indicates a vacuum value later.

Expansion valve is frozen due to entry of moisture.

- Inspect expansion valve, replace if needed. - Replace receiver dryer. - After finishing work, evacuate system completely and recharge.

Symptom

Cause

Inspection/action point

- Pressure on low pressure side is unusually high, and pressure on high pressure side is unusually low.

Compressor is defective.

- Review 2nd symptom.

- Shortly after air conditioner turns off, pressure becomes equal between high pressure side and low pressure side.

- If pressure in compressor is low, compressor will not build much heat due to lack of pressure. - Replace compressor. - After finishing work, evacuate system and recharge.

65ZV-2 US 72-91 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

When there is too much refrigerant or cooling in the condenser is insufficient <Low pressure side> 245~343 kPa (2.5~3.5 kgf/cm2) (35~50 psi)

When air has entered into the cooling circuit

<Low pressure side> 245~294 kPa (2.5~3.0 kgf/cm2) (35~43 psi)

<High pressure side> 1,961~2,452 kPa (20~25 kgf/cm2) (284~355 psi)

97ZV72097

97ZV72096

Symptom

Cause

Inspection/action point

Symptom

Cause

Inspection/action point

- Pressure is high on both low pressure side and high pressure side.

- Refrigerant quantity is too much.

- Check and correct refrigerant charge pressure.

- Pressure is high on both low pressure side and high pressure side.

Air has entered system.

- Refrigerant is bad.

- Plugged or bent condenser fins.

- Inspect and repair condenser fins.

- Even when engine rpm’s (min-1) are reduced, gas bubbles cannot be seen at all in sight glass. - Air in cab does not become cool enough.

- Bad fan motor or fan blade. - Heat transfer does not occur in evaporator has plugged fins

- Repair or replace fan or fan motor - Inspect and repair evaporator fins.

- Low pressure piping is not cold.

- Evacuate system completely.

- Gas bubbles go through sight glass.

- Replace refrigerant.

65ZV-2 US 72-92 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

When the expansion valve is opened too much <Low pressure side> 294~392 kPa (3.0~4.0 kgf/cm2) (43~57 psi)

<High pressure side> 1,961~2,452 kPa (20~25 kgf/cm2) (284~355 psi)

97ZV72098

Symptom

Cause

Inspection/action point

- Pressure is high on both low pressure side and high pressure side.

Expansion valve is defective.

- Temperature sensing rod may be sticking. - Inspect expansion valve. Check temp in and out of valve to determine if it is operating correctly.

- Condensation forms on low pressure side pipes.

Thermal expansion valve

To and from evaporator

Diaphragm

Spring

Temperature sensing rod Needle valve Compressor return From receiver dryer

97ZV72049

65ZV-2 US 72-93 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

Air conditioner troubleshooting

Display

Fault diagnosis procedure

Hearing check

Error code check ∗

Phenomenon check

Basic check In accordance with fault phenomenon

1) Control mechanism 2) V-belt 3) Sight glass 4) Piping connection

Refrigerant cycle check - Pressure check - Gas leak check

 Error code table

Electrical system check

Repair/check

End

80V2E01012

Failure mode

E-

No failure

E11

Wire breakage in inside air sensor

E12

Short-circuit in inside air sensor

E13

Wire breakage in outside air sensor

E14

Short-circuit in outside air sensor

E15

Wire breakage in water temperature sensor

E16

Short-circuit in water temperature sensor

E18

Short-circuit in insolation sensor

E21

Wire breakage in vent sensor

E22

Short-circuit in vent sensor

E43

Abnormality in vent damper

E44

Abnormality in air mixing damper

E45

Abnormality in inside/outside air

E51

Abnormality in refrigerant pressure

65ZV-2 US 72-94 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~) Basic check 1. Check of control mechanism Operate the switch arranged on the control panel, to check that it is operable smoothly and securely. 2. Check of V-belt Check that the V-belt is tensioned properly, and that it is not damaged. 3. Check of refrigerant level through sight glass When the air bubble is observed a lot through sight glass, the refrigerant is probably insufficient. In such a case, therefore, perform the checking with using a gauge manifold.

Sight glass

Receiver joint

Receiver drier

95ZVE01003

4. Check of piping connection At the piping connection where the oil stain is seen, there is probably a refrigerant leakage. In such a case, remove the stain, and then check for gas leakage.

Cooling failure

Normal air flow rate

With diagnostic display: E51 (refrigerant high/ lower pressure error)

With diagnostic display: E44 (A/M servo motor error)

Without diagnostic display

Air flow rate failure

Close the window and door. Adjust the inside/outside air changeover damper. Re-set the link.

See D-2 .

See D-1 .

See C-3 .

Check the wiring. Replace the servo motor with a new one. Remove the foreign matter.

Replace the V-belt with a new one. Replace the compressor with a new one. Repair the magnet switch, or replace it with a new one. Check the wiring.

Insufficient refrigerant.

See C-4 . See C-5 .

See C-1 .

Servomotor failure Blocked foreign matter

Wiring failure, disconnection, disengaged connector

Magnet clutch failure Clutch engagement failure due to electrical system failure

Broken or slipped belt Compressor failure (locking)

High pressure both at high-pressure side and low-pressure side Low pressure both at high-pressure side and low-pressure side

Too low pressure at high-pressure side(Pressure is not increased to approx. 981kPa[10kgf/cm2] or over) Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less

See C-2 . See C-3 .

∗ Examine the cause before taking the corrective measure,and then replace the fuse with that of the same capacity. See B-1 . Replace the blower main relay with a new one. Replace the blower motor with a new one. Correct the interference. Replace the panel with a new one. Earth the body securely. Check the wiring. Replace the motor with a new one.

Examine the cause of over-voltage before taking the corrective measure.

Check the battery charging system. Correct the contact failure. Replace the blower motor with a new one. Replace the BLC with a new one.

Too high pressure at low-pressure side(approx. 294kPa[3kgf/cm2] or over)

Disengaged A/M link

Mixing of outside air

Operation of BLC protective function due to locked motor

Blower switch failure Body earth failure Wiring failure, disconnected connector

Blown fuse Blower main relay failure Blower motor failure Interference of blower with case

Operation of BLC over-voltage protective function

Decreased supply voltage Battery terminal contact failure Blower motor rotation failure BLC failure

See A-1 .

Operation of low-pressure cut function

Pressure error

Normal pressure

Rotation failure for all modes

Blower is rotated only when the fan switch is selected to High-speed position.

Slow rotation

Adhesion of dust to surface of evaporator

Deformed or damaged blower Frosting in evaporator

Existence of obstacle at vicinity of suction port

Clean the filter. Clean the filter. Remove the obstacle. Replace the blower with a new one. Stop the air compressor, to melt the ice. Examine the cause before taking the corrective measure. Clean the surface of evaporator.

Operation of high-pressure cut function

Compressor rotation failure

Compressor normal rotation

Blower motor rotation failure

Blower motor rotation

Normal rotation

Clogged inner air filter Clogged outer air filter

65ZV-2 US 72-95 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

80V2E01013

C-2

C-1

B-1

A-1

Voltage not applied to magnet clutch

Voltage applied to magnet clutch Check for characteristic.

Clogging of dust or mud, etc. in fin.

Excessively opened expansion valve

Replace the valve with a new one. Correction Contact failure in pressure needle valve

Replace the compressor with a new one.

Valve failure

Foreign matter caught by suction valve

Broken suction valve

Discharge the refrigerant to proper level.

Over-filled refrigerant Broken head gasket

Fully discharge the refrigerant, and execute the evacuation, and fill the refrigerant again to proper level.

Mixing of air during refrigerating cycle

Compressor failure

Discharge the refrigerant to proper level.

Over-filled refrigerant

Insufficiently cooled condenser

Clean(Washing with water) the fin.

Check the wiring.

Unusually high outside air temperature

Perform the checking, referring to the wiring diagram.

Evaporator

Sort-circuit wiring

Replace the blower motor with a new one.

Replace the magnet clutch with a new one. Thermister (frosting sensor)

12 ± 5 mm (0.5 ± 0.2 in)

Adjust the gap (12 ± 5 mm) (0.5 ± 0.2 in).

Replace the thermister(frosting sensor) with a new one.

Correction

Replace the clutch relay with a new one.

Erroneous wiring

Locked blower motor

Magnet clutch failure

Adjustment failure of gap between the thermister(frosting sensor) and evaporator

Check the short-circuit.

Thermister(frosting sensor) characteristic failure

Check the clutch circuit.

Thermister(frosting sensor) wiring failure

Magnet clutch circuit failure

65ZV-2 US 72-96 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

85V2U72008

C-5

C-4

C-3

Over-filled refrigerant

Clogging of dust or mud, etc. in fin.

Discharge the refrigerant to proper level.

Clean(washing with water) the fin.

Execute the evacuation fully after replacing the valve and receiver with a new one respectively.

Temporary clogging(mixing of moisture content) due to frozen valve

Insufficiently cooled condenser

Replace the valve with a new one.

Relieved gas from pressure needle valve

to A-1

Replace the valve with a new one.

Replacement

Clogged valve(mixing of foreign matter)

Clogging due to foreign matter in the course of piping

Clogged receiver & drier

Perform the leak test and repair the location of failure before filling the refrigerant.

Gas leakage

Execute the evacuation fully after replacing the valve and receiver with a new one respectively.

Clogging(mixing of moisture content) due to frozen valve

Fill the refrigerant to proper level.

Replace the valve with a new one.

Relieved gas from pressure needle valve

Limited amount of refrigerant filled

Replace the valve with a new one.

Clogged valve(mixing of foreign matter)

Suction/discharge valve failure

Locked piston

Replace the compressor with a new one.

Perform the leak test and repair the location of failure before filling the refrigerant.

Gas leakage

Swash plate shoe seizure

Fill the refrigerant to proper level.

Limited amount of refrigerant filled

Frosted evaporator

Expansion valve failure

Clogging during refrigerating cycle

Limited refrigerant

Unusually low outside air temperature

Expansion valve failure

Compressor failure

Limited refrigerant

Unusually low outside air temperature

65ZV-2 US 72-97 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

80V2E01015

D-2

D-1

C-4

Replacement

High/low-pressure switch failure

C-1

Replacement

Thermo-sensor failure

Excessively low pressure [981 kPa(10kgf/cm2)or lower]

Replacement

Compressor clutch relay failure

High-pressure error

Replace the control panel with a new one.

Excessively high pressure [2452 kPa(25kgf/cm2)or over]

Replace the control panel with a new one.

Blower switch failure

Re-charging

Battery voltage drop

Air conditioner switch failure

Replacement

Rare-short in coil

Disassembling/repair

Remove the oil.

Stained clutch surface due to oil

Foreign matter caught between rotor and stator

Replace the key with a new one.

Repair or replacement Slippage due to broken key or key insertion failure

Excessive air gap between rotor and stator Slipped clutch

Replacement

Disconnected stator coil

65ZV-2 US 72-98 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

80V2E01016

Leakage of water in operator's cab

Heating failure

Normal wind force

Insufficient wind force

Fill the coolant to proper level. Replace the heater core with a new one.

Limited engine cooling water Broken heater core

Replacement

Cleaning

Check the wiring.

Servo motor failure

Remove the foreign matter.

Foreign matter caught

Wiring failure, disconnection, disconnected connector

Re-set the link.

Disengaged temperature controller link

IN side and OUT side reversed.

The temperature controller LED is not operated properly.

Clogged drain hole

Repair or replacement

Clogged or bent piping Excessively low outside air temperature

Discharge the air.

The air is mixed in hot-water circuit.

Note: Do not fail to check that the pump pressure is normal, and that the heater hose is not connected with

The temperature controller LED is operated properly.

Normal water temperature

Low water temperature

Same as "Cooling failure"

65ZV-2 US 72-99 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

85V2U72009

(without inside air sensor error)

Without diagnostic display

(short-circuit inside air sensor)

higher or lower than

setting temperature

With diagnostic display: E12

(disconnected inside air sensor)

With diagnostic display: E11

(inside air/outside air servo motor abnormal)

With diagnostic display: E45

(inside air/outside air servo motor normal)

Without diagnostic display

(blow-off servo motor abnormal)

With diagnostic display: E43

Room temperature

changeover failure

Outside air/inside air

failure

Blow-off changeover

(blow-off servo motor normal)

Without diagnostic display

Cooling failure, heating failure

Short-circuit inside air sensor

Perform the checking in accordance with the paragraph "Cooling failure/heating failure".

Replacement

Check the wiring.

Replacement

Disconnected inside air sensor Short-circuit harness

Re-check the wiring.

Remove the foreign matter.

Foreign matter caught

Disconnected harness, disengaged connector

Replacement

Re-check the wiring

Wiring failure, disconnection, disconnected connector Servo motor failure

Re-set the link.

Remove the foreign matter.

Foreign matter caught

Disengaged link

Replacement

Check the wiring.

Wiring failure, disconnection, disconnected connector Servo motor failure

Re-set the link.

Disengaged link

65ZV-2 US 72-100 72 Function & Structure Operator Station Group Air Conditioner (S/N 5051~)

80V2E01018

65ZV-2 US 73-1 73 Check & Adjustment Operator Station Group

73 Check & Adjustment Operator Station Group Air Conditioner ........................................................ 73-2

65ZV-2 US 73-2 73 Check & Adjustment Operator Station Group Air Conditioner

Air Conditioner Adjustment of lubricating oil quantity when components of air conditioner are replaced

WARNING In order to protect the environment, do not release refrigerant to atmosphere when removing components from air conditioner system. It not illegal to do so.

IMPORTANT

Fig. 1 97ZV73002

- When replacing components of the air conditioner, if the lubricant oil quantity is too small, the compressor may seize. And if the lubricating oil quantity is too much, the cooling ability may lessen. Use the correct amount of compressor lube oil. - When connecting a joint, apply compressor oil (ND-OIL 8) on the O ring before tightening (Fig. 1). - If the compressor oil (ND-OIL 18) is applied to paint, paint may peel or otherwise be damaged. If it gets on a painted surface, quickly wipe it off. - Tighten the piping, etc. at the recommended torque. Tightening torque table Connection area

Nut type (Fig. 2) Fig. 2 97ZV73003

Block joint (Fig. 3)

Fig. 3

97ZV73004

Pipe size or bolt size

Tightening torque N-m (kgf-cm) (lb-ft)

ø8 pipe

14.7 (150) (7)

1/2 pipe

24.5 (250) (18)

5/8 pipe

34.3 (350) (25)

M6 bolt in receiver (4T)

6.9 (70) (5)

Any M6 bolt other than above (6T)

11.8 (120) (9)

65ZV-2 US 73-3 73 Check & Adjustment Operator Station Group Air Conditioner

When the compressor is replaced

New compressor

Torque values

Old compressor to be replaced

Compressor mounting bolt 29 N-m (3.0 kgf-m) (22 lb-ft) Hose block joint on high pressure side 12 N-m (1.2 kgf-m) (9 lb-ft) Hose block joint on low pressure side 12 N-m (1.2 kgf-m) (9 lb-ft)

Oil quantity remaining inside circuit

Example (B)

Suppose that the oil quantity (A) removed from the compressor to be replaced is 100 cm3. See figure 1.

A Fig. 1 97ZV73005

To avoid overloading the circuit; 1. Remove the oil from the removed (old) compressor, measure and record the oil quantity. (Approximately 20 cm3 (0.7 oz) of oil cannot be removed, and remains inside the compressor.)................ A cm3 2. The compressor can hold about 180 cm3 (6.1 oz; or 0.76 cup) of oil. Determine the system’s remaining oil quantity using the following equation. Oil quantity remaining inside circuit is: = 180 cm3 - (Oil quantity A discharged; see fig. 1. from removed compressor + 20 cm3) 3. Drain as much oil from the compressor as the quantity remaining inside the refrigerant circuit. When finished, mount the new compressor. Compressor lubricating oil ND-OIL 8 (Nihon Denso oil 8; Polyalkalene glycol (PAG) oil)

IMPORTANT 3

- Oil (180 cm ; or 0.76 cup) required for the cooling circuit is sealed inside a new compressor. Prior to replacing the compressor, excess oil should be drained from the new compressor. - The compressor oil can come to absorb moisture. Seal the compressor immediately after adjusting the oil quantity with a plastic cap. - Never use ester based oil. Use only PAG oil.

Oil quantity remaining inside circuit (B) = 180 cm3 - (100 + 20) = 60 cm3 Remove 60 cm3 from the new compressor to avoid overloading the circuit.

65ZV-2 US 73-4 73 Check & Adjustment Operator Station Group Air Conditioner

When the evaporator is replaced

When the condenser is replaced Quantity of lubricating oil lost by replacement of condenser is approximately 40 cm3 (1.35 oz).

When replacing the condenser core, add 40 cm3 (1.35 oz) of compressor oil (ND-OIL 8) to a new condenser. : (1): 25 N-m (2.5 kgf-m) (18 lb-ft) : (2): 15 N-m (1.5 kgf-m) (11 lb-ft)

Evaporator

When the receiver dryer is replaced Quantity of lubricating oil lost by replacement of receiver dryer is approximately 20 cm3 (0.7 oz).

Expansion valve

The amount of oil loss by replacement of the receiver dryer is within the allowable range, and adding oil is not needed if this is the first replacement of the condenser core. At the next time the dryer is replaced and from then on, add 20 cm3 (0.7 oz) of compressor oil (ND-OIL 8) to a new receiver dryer.

97ZV73006

Quantity of lubricating oil lost by replacement of evaporator core is approximately 40 cm3 (1.35 oz). When replacing the evaporator, add 40 cm3 (1.35 oz) of compressor oil (ND-OIL 8) to a new evaporator. : (1): 12 N-m (1.2 kgf-m) (9 lb-ft)

: (1): 7 N-m (0.7 kgf-m) (5 lb-ft) : (2): 15 N-m (1.5 kgf-m) (11 lb-ft)

65ZV-2 US 73-5 73 Check & Adjustment Operator Station Group Air Conditioner

Adjustment of air gap (between hub and rotor) in compressor magnetic clutch

1. Remove the front cover of the magnetic clutch. 2. Measure dimension A between rotor end face and hub end face while magnetic clutch is "OFF". 3. Apply the battery voltage directly on the connector of the magnetic clutch, and measure the size of B in the same way as step 2 above. Note the difference.

Position while magnetic clutch is OFF

A (OFF status) Position while magnetic clutch is ON

Reference plane Air gap 0.50±0.15 mm (0.020±0.006 in)

Standard (normal dimension) of air gap (A - B) 0.50±0.15 mm (0.020±0.006 in) If the obtained value does not agree with the criteria, loosen the head bolt, remove the hub, and adjust the air gap by adjusting the thickness of the washer plate between the hub and the shaft.

B (ON status)

Hub Head bolt Washer plate

Rotor

95ZVE73002

WARNING Shut off the engine to do this procedure. If you try to adjust air gap while engine is "ON", a serious accidents would occur. Turn starter switch "OFF", stop rotation of engine tag out unit, pull out starter key, then start adjustment. Use a "Do Not Start" tag on the machine when performing this work.

65ZV-2 US 73-6 73 Check & Adjustment Operator Station Group Air Conditioner

Compressor V-belt adjustment (S/N 5001~5050) (Bergstrom) A 3 7

3 6 8

4 1

5 8 6 4

A-A K65V2E73001

1. Compressor 2. Bracket mounting nut 3. Lock nut 4. Adjusting nut 5. V-belt 6. Bracket 7. Bolt 8. Plate

65ZV-2 US 73-7 73 Check & Adjustment Operator Station Group Air Conditioner

Belt adjustment procedure 1. Loosen four bracket mounting nuts (2). 2. Loosen lock nut (3). Turn adjusting nut (4) clockwise to tighten V-belt (5) by sliding bracket (6) upward. Turn adjusting nut (4) counterclockwise to loosen the V-belt. 3. After the adjustment, tighten the lock nut, adjusting nut and the bracket mounting nuts securely.

8~10 mm (0.3~0.4 in)

Belt adjustment value

98.1 N (10 kgf)

K80V2J73001

Adjust the V-belt tension so that the belt bends by 8~10 mm (0.3~0.4 in) when applying 98.1 N (10 kgf) (22 lbf) force to the middle of pulleys.

65ZV-2 US 73-8 73 Check & Adjustment Operator Station Group Air Conditioner

Compressor V-belt adjustment (S/N 5051~) (DENSO) A

7 7

1 3 6 8

A 8

4 1

A-A K65V2E73002

1. Compressor 2. Bracket mounting nut 3. Lock nut 4. Adjusting nut 5. V-belt 6. Bracket 7. Bolt 8. Plate

65ZV-2 US 73-9 73 Check & Adjustment Operator Station Group Air Conditioner

Belt adjustment procedure 1. Loosen four bracket mounting nuts (2). : Bracket mounting nut (2): 53.0 N-m (5.4 kgf-m) (39 lb-ft) 2. Loosen lock nut (3). Turn adjusting nut (4) clockwise to tighten V-belt (5) by sliding bracket (6) upward. Turn adjusting nut (4) counterclockwise to loosen the V-belt. : Lock nut (3): 53.0 N-m (5.4 kgf-m) (39 lb-ft) Adjusting nut (4): 53.0 N-m (5.4 kgf-m) (39 lb-ft) 3. After the adjustment, tighten the lock nut, adjusting nut and the bracket mounting nuts securely.

Belt adjustment value

85V2E73002

Adjust the V-belt tension so that the belt tension at A part is 441±88 N (45±9 kgf) (99±20 lbf) by using tension gauge. Note The V-belt tension should be 637±108 N (65±11 kgf) (143±24 lbf) when the belt is replaced with new one.

65ZV-2 US 73-10 73 Check & Adjustment Operator Station Group Air Conditioner

Parts to be replaced periodically

Receiver dryer

Air filters

Replacement Once every 3 years or 6,000 hours

Air filter for outside air Cleaning Once every 2 weeks or when required. However, if the operating environment is severe (with much sand, dust, etc.) and the air filter is easily clogged, clean it more frequently. To clean, blow filter with compressed air of 196~294 kPa (2~3 kgf/cm2) (28~43 psi) mainly from inside of filter. Replacement Once each year or when required. When air flow volume is so small as to affect air movement even after the filter has been cleaned, or when the air filter has been cleaned 20 times, replace it.

Air filters for inside air Cleaning Once each month However, if the air filters are easily clogged, clean them more frequently. To clean, blow filter with compressed air of 196~294 kPa (2~3 kgf/cm2) (28~43 psi) mainly from inside of the filter. Replacement Once every 3 years When air flow volume is so small as to affect air movement even after the filter has been cleaned, or when the air filter has been cleaned 6 times, replace it.

Note When replacing the receiver dryer, do not release the refrigerant into the atmosphere.

INDEX 134A refrigerant compressor ............................................72-6 1st and 2nd speed clutch ................................................32-11 3rd and 4th speed clutch ................................................32-12 3rd, 4th speed control valve ............................................32-23

A A/C Charging ..................................................................72-32 Accelerator pedal ............................................................62-22 Accumulator ............................................... 32-29, 42-70, 52-8 Accumulator (for ride control) .........................................42-52 Accumulator for 1st and 2nd speed clutch ......................32-29 Accumulator function ......................................................42-52 Accumulator low pressure sensor .....................................52-7 Adapter (Orifice) .............................................................42-42 Adjustable declutch preset switch ...................................62-35 Adjusting set pressure ........................................ 42-33, 42-35 Adjusting shim ..................................................................13-4 Adjusting steering line main pressure ...............................43-9 Adjustment ........................................................................13-3 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch .........................................73-5 Adjustment of axle internal pressure ................................52-2 Adjustment of lubricating oil quantity when components of air conditioner are replaced ......................................73-2 Adjustment procedure .....................................................53-10 After power-off (clutch disengaged status) .....................32-30 After power-on (clutch engaged status) ..........................32-31 Air compressor (with magnetic clutch) ............................72-41 Air Conditioner ..................................................................73-2 Air Conditioner (S/N 5001~5050) ......................................72-2 Air Conditioner (S/N 5051~) ............................................72-37 Air conditioner functions of components .........................72-48 Air conditioner specifications (system performance) ......72-37 Air conditioner troubleshooting ........................... 72-19, 72-93 Air conditioner unit ..........................................................72-55 Air conditioning systems ...................................................72-2 Air conditioning unit ..........................................................72-2 Air distributor (hood & defroster selection box) ...............72-40 Air filters ..........................................................................73-10 All setting reset ...............................................................62-89 Alternator ........................................................................62-16 Alternator L terminal wire ................................................62-12 Appendix .........................................................................72-35 Automatic shift ................................................................62-32 Auxiliary valves ...............................................................42-67 Axle Assembly ........................................................ 22-9, 92-2 Axle Support ...................................................................22-10

B Back-up alarm .................................................................62-37 Basic tools needed to work on air conditioning ...............72-28 Battery relay ....................................................................62-12 Battery relay operation ....................................................62-12 Before the shift lever is moved (traveling or stop condition) (high pressure holding) ..............................32-26 Belt adjustment procedure ...................................... 73-7, 73-9

Belt adjustment value .............................................. 73-7, 73-9 Bergstrom air conditioner structure .................................. 72-3 Bleeding air from brake pipes ......................................... 52-16 Bolt tightening torque ..................................................... 00-13 Boom cylinder ................................................................. 42-20 Boom spool operation .................................................... 42-39 Brake Circuit ..................................................................... 92-6 Brake circuit air bleeding procedure ............................... 52-16 Brake Circuit Check Valve .............................................. 52-23 Brake Circuit Oil Pressure ................................................ 53-2 Brake lining abrasion check ........................................... 53-10 Brake System Outline ....................................................... 52-2 Brake Units Layout ........................................................... 52-3 Brake Valve .................................................................... 52-10 Brake valve oil pressure ................................................... 53-4 Brake valve oil pressure measurement ............................ 53-4 Brake valve outline ......................................................... 52-12 Brake valve performance ................................................. 53-5 Brake valve performance chart ...................................... 52-11 Bucket cylinder ............................................................... 42-21 Bucket leveler ................................................................. 62-92 Bucket spool operation ................................................... 42-37

C Caution for diode check method ................................... 62-100 Cautions on Hydraulic Parts Replacement ....................... 42-3 Cautions on Safety ........................................................... 03-2 Cautions regarding parts removal .................................. 00-18 Cautions regarding reassembly ...................................... 00-18 Cautions regarding welding repair service ..................... 00-20 Center Pin ............................................................... 12-8, 13-4 Changing display from one function to next ................... 62-54 Charge amounts ............................................................. 72-33 Charge of refrigerant ...................................................... 72-76 Check valve ...................................................................... 42-6 Checking actuators ......................................................... 72-25 Checking voltage at connectors ..................................... 72-24 Clear active fault log (error pop up) (S/N 5001~5014 only) ................................................ 62-69 Clear fault log ................................................................. 62-68 Clutch combination ........................................................... 32-4 Clutch control oil pressure curve .................................... 32-25 Clutch Oil Pressure .......................................................... 33-2 Clutch Pack .................................................................... 32-10 Clutch Solenoid Valve .................................................... 32-30 Clutch specifications ......................................................... 32-8 Coil box unit ...................................................................... 72-4 Compressor and magnetic clutch ................................... 72-64 Compressor details .......................................................... 72-7 Compressor electro-magnetic drive clutch ....................... 72-7 Compressor V-belt adjustment (S/N 5001~5050) (Bergstrom) .................................................................. 73-6 Compressor V-belt adjustment (S/N 5051~) (DENSO) ...................................................................................... 73-8 Condenser ........................................................................ 72-8 Condenser unit .................................................... 72-41, 72-67 Connection diagram ....................................................... 62-17

Connector ....................................................................... 62-25 Contact between pinion and side gear ........................... 22-16 Continuity check mode ................................................. 62-100 Control panel ....................................................... 72-14, 72-48 Control schematic drawing ............................................. 72-47 Control unit ..................................................................... 72-42 Control Valve .................................................................. 32-23 Coolant ........................................................................... 00-10 Coolant specification ...................................................... 00-10 Cooling circuit ................................................................. 72-46 Cooling unit .................................................................... 72-38 Cylinder natural drift ....................................................... 43-11 Cylinders .......................................................................... 42-4

D Defroster/Operator ventilation and heater valve actuator motors .......................................................... 72-13 Denso air conditioner components ................................. 72-37 Denso air conditioner structure ...................................... 72-38 Detent solenoid ................................................... 62-94, 62-98 Diagnosis trouble code (DTC) information ..................... 62-19 Difference in gear shapes .............................................. 22-16 Differential Gear ............................................................. 22-12 Diode .............................................................................. 62-99 Diode check method ..................................................... 62-100 Diode check mode ........................................................ 62-100 Diode unit ....................................................................... 62-13 Directional control valve ................................................... 42-6 Disclaimer ....................................................................... 72-32 Display language ............................................................ 62-66 Downshift button operation .................................... 32-4, 62-34 Dust seal .......................................................................... 12-9 Dynamic signal ............................................................... 42-59

E ECM (Engine Controller) ................................................ 62-17 Efficient Loading System (OPT) ..................................... 42-72 Efficient loading system operation .................................. 42-76 Efficient loading system outline ...................................... 42-72 Electrical Cable Color Codes ........................................... 62-3 Electrical circuit .............................................................. 72-47 Electrical Circuit Diagram (Cabin Air Conditioner) (S/N 5051~) ............................................................... 92-40 Electrical Circuit Symbols ................................................. 62-4 Electrical Connection (Cabin Air Conditioner) (S/N 5001~5050) ....................................................... 92-38 Electrical Connection Diagram (1/2) (S/N 5001~5050) .................................................................................... 92-30 Electrical Connection Diagram (1/2) (S/N 5051~5100) .................................................................................... 92-32 Electrical Connection Diagram (1/2) (S/N 5101~5400) .................................................................................... 92-34 Electrical Connection Diagram (1/2) (S/N 5401~) .......... 92-36 Electrical Connection Diagram (2/2) (S/N 5001~5050) .................................................................................... 92-31 Electrical Connection Diagram (2/2) (S/N 5051~5100) .................................................................................... 92-33 Electrical Connection Diagram (2/2) (S/N 5101~5400) .................................................................................... 92-35

Electrical Connection Diagram (2/2) (S/N 5401~) ...........92-37 Electrical Detent Circuit ..................................................62-92 Electrical Equipment Layout ...........................................92-42 Electrical pins locations ..................................................72-16 Electrical Wiring Diagram ...............................................92-23 Electrical Wiring Diagram (1/4) (S/N 5001~5050) .............92-7 Electrical Wiring Diagram (1/4) (S/N 5051~5100) ...........92-11 Electrical Wiring Diagram (1/4) (S/N 5101~5400) ...........92-15 Electrical Wiring Diagram (1/4) (S/N 5401~) ...................92-19 Electrical Wiring Diagram (2/4) (S/N 5001~5050) .............92-8 Electrical Wiring Diagram (2/4) (S/N 5051~5100) ...........92-12 Electrical Wiring Diagram (2/4) (S/N 5101~5400) ...........92-16 Electrical Wiring Diagram (2/4) (S/N 5401~) ...................92-20 Electrical Wiring Diagram (3/4) (S/N 5001~5050) .............92-9 Electrical Wiring Diagram (3/4) (S/N 5051~5100) ...........92-13 Electrical Wiring Diagram (3/4) (S/N 5101~5400) ...........92-17 Electrical Wiring Diagram (3/4) (S/N 5401~) ...................92-21 Electrical Wiring Diagram (4/4) (S/N 5001~5050) ...........92-10 Electrical Wiring Diagram (4/4) (S/N 5051~5100) ...........92-14 Electrical Wiring Diagram (4/4) (S/N 5101~5400) ...........92-18 Electrical Wiring Diagram (4/4) (S/N 5401~) ...................92-22 Electrical Wiring Diagram (CAB) .....................................92-27 Electrical Wiring Diagram (Cabin Air Conditioner) (S/N 5051~) ................................................................92-39 Electrical wiring diagram abbreviation chart ...................92-25 Emergency check valve ..................................................42-69 Engine ...............................................................................23-2 Engine / Transmission ......................................................22-3 Engine / transmission mount ............................................22-3 Engine fault log navigation ..............................................62-68 Engine Start Circuit ...........................................................62-9 Engine start circuit diagram ..............................................62-9 Equipment Operation Table (Cabin Air Conditioner) (S/N 5051~) ................................................................92-41 Evaporator ......................................................................72-10 Evaporator core and temperature sensor .......................72-10 Evaporator thermal switch ..............................................72-11

F Fan box unit ......................................................................72-5 Fan motor (S/N 5001~5054) ...........................................42-85 Fan motor (S/N 5055~) ...................................................42-87 Fan Motor Line ................................................................42-79 Fan Motor System ..........................................................42-78 Fan motor system .............................................................42-9 Fault diagnosis procedure ..............................................72-93 Fault log history check ....................................................62-66 Fault Log Monitor ............................................................62-66 Final inspection ...............................................................72-34 Flanged hexagon bolt .....................................................00-16 Floor board .......................................................................12-7 Floor board mount ............................................................12-7 Flow control solenoid valve .............................................42-84 Flow control valve ................................................. 42-5, 42-83 Flushing Hydraulic Circuit .................................................42-2 For forward/reverse and speed clutches ........................32-30 Forward 1st speed power flow path ................................32-13 Forward 2nd speed power flow path ...............................32-14 Forward 3rd speed power flow path ...............................32-15 Forward 4th speed power flow path ................................32-16

Forward and reverse clutch ............................................32-10 Forward/reverse (F/R) shifting and speed change .........62-30 Friction plate: mm (in) .......................................................32-8 From torque converter gear pump to torque converter ....................................................................................32-20 Front Chassis ....................................................................12-2 Front differential – Transmission ......................................22-7 Fuel level sensor .............................................................62-50 Fuel tank (S/N 5001~5128) ...............................................12-5 Fuel tank (S/N 5029~) .......................................................12-6 Function of ECM .............................................................62-17 Function of T.P.D ............................................................22-16 Fuse ..................................................................................62-6 Fuse box ...........................................................................62-6 Fusible link ........................................................................62-8

G Gauge circuit ...................................................................62-48 Gear train and number of teeth .........................................32-5 General charging procedure ...........................................72-32 General inspection points ...............................................72-34 General tips for working on A/C systems ........................72-26

H Heater and accessories ..................................................72-40 Helpful hints ....................................................................72-26 Hexagon bolt ...................................................................00-13 High pressure switch ......................................................72-12 Hose band tightening torque ...........................................00-17 How to Use Electrical Wiring Diagram ..............................62-2 How to Use Manual ..........................................................00-2 How to wind a seal tape ..................................................00-19 Hydraulic & Brake Circuit ..................................................92-5 Hydraulic circuit (fan motor normal rotation) ...................42-82 Hydraulic circuit (Reverse rotation) .................................42-92 Hydraulic Circuit Diagram ...............................................32-19 Hydraulic Cylinder ............................................... 42-20, 43-11 Hydraulic cylinder specifications .....................................42-22 Hydraulic lines ..................................................................42-4 Hydraulic oil level check .................................................42-16 Hydraulic Pump ..............................................................42-17 Hydraulic pump bushing lubrication ................................42-19 Hydraulic pump oil amount and steering force ...............42-64 Hydraulic pump principle ................................................42-18 Hydraulic pump specifications ........................................42-17 Hydraulic pump wear plate .............................................42-19 Hydraulic System Diagram .............................................32-18 Hydraulic System Operation .............................................42-8 Hydraulic system operation outline ...................................42-8 Hydraulic Tank ................................................................42-11 Hydraulic Tank (S/N 5001~5200) ...................................42-11 Hydraulic Tank (S/N 5201~) ...........................................42-13 Hydraulic tank breather valve (tank cap)(S/N 5001~5200) ....................................................................................42-12 Hydraulic tank breather valve (tank cap)(S/N 5201~) .....42-14 Hydraulic tank specifications ..........................................42-15

I Information Monitor .........................................................62-56

Information monitor display ............................................ 62-56 Inlet check valve ............................................................. 42-69 In-Line Filter ..................................................................... 52-9 Input/Output Monitor ....................................................... 62-73 Input/Output monitor display .......................................... 62-73 Inspection and maintenance table .................................... 00-5 Instrument panel ............................................................. 62-44 Instrument Panel and Switch .......................................... 62-44 Instrument panel rear surface ........................................ 62-46 Items to be monitored and operation condition .............. 62-42

L Layout of Hydraulic Units ............................................... 42-10 Layout of main components ............................................. 00-4 Layout of ports on mounting surface of control valve (at T/M case side) ...................................................... 32-24 Leak ............................................................................... 72-33 Leak check ..................................................................... 72-33 Lift kickout ...................................................................... 62-95 Lift kickout & lower kickout ............................................. 62-95 Limited Slip Differential (option) ..................................... 22-18 Liner ................................................................................. 13-2 Linkage Pin ....................................................................... 13-2 Liquid gasket and screw lock agent ............................... 00-18 Loading circuit relief valve setting pressures .................... 43-2 Loading linkage ................................................................ 12-2 Loading linkage pin .......................................................... 12-4 Loading System .............................................................. 42-23 Loading system ................................................................ 42-8 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ...................................... 43-2 Load-sensing system ..................................................... 42-59 Location .......................................................................... 62-95 Low pressure switch ....................................................... 72-12 Lower center pin ............................................................... 12-8 Lower kickout ................................................................. 62-95 LSD function ................................................................... 22-21 LSD operation ................................................................ 22-21 Lubrication chart ............................................................. 00-11

M Machine control unit (MCU) ............................................ 62-24 Machine control unit (MCU) connection diagram (S/N 5001~5400) ....................................................... 62-26 Machine control unit (MCU) connection diagram (S/N 5401~) ............................................................... 62-28 Machine control unit (MCU) failure warning ................... 62-40 Machine control unit (MCU) function .............................. 62-30 Machine fault log navigation ........................................... 62-68 Machine speed sensor ................................................... 62-33 Main control valve .......................................................... 32-23 Main relief valve operation ............................................. 42-32 Maintenance ................................................................... 72-26 Make-up valve operation ................................................ 42-36 Measuring clutch oil pressure ........................................... 33-2 Measuring engine oil pressure ......................................... 23-2 Measuring engine speed .................................................. 23-2 Measuring loading circuit main relief pressure ................. 43-4 Measuring loading circuit overload relief pressure ........... 43-4

Measuring pilot circuit relief pressure ............................... 43-5 Measuring ride control circuit reducing pressure .............. 43-7 Measuring steering circuit main relief pressure ................ 43-9 Measuring steering circuit overload relief pressure ........ 43-10 Miscellaneous hydraulic symbols ..................................... 42-7 MODM ............................................................................ 62-53 MODM function .............................................................. 62-53 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table .............................................. 92-68 Modulation Mechanism .................................................. 32-25 Modulation mechonism operation .................................. 32-26 Monitor Changeover ....................................................... 62-53 Monitor lamp test ............................................................ 62-18 Monitoring system .......................................................... 62-42 Mounting of fan motor .................................................... 42-78 Mounting of the ELS valve ............................................. 42-73 Mounting of the variable kickout sensor ......................... 42-75 Multiple Control Valve (KML22/2T) ................................ 42-30 Multiple control valve boom spool .................................. 42-39 Multiple control valve bucket spool ................................. 42-37 Multiple control valve main relief valve ........................... 42-32 Multiple control valve make-up valve ............................. 42-36 Multiple control valve overload relief valve (with make-up function) .............................................. 42-34 Multiple control valve specifications ............................... 42-31

N Neutral ............................................................................ 42-61 Neutral relay ................................................................... 62-14 Neutral starter ................................................................. 62-10 Non-load reaction system ............................................... 42-59

O Oil Flow .......................................................................... 32-20 Oil flow change when Q/Amp. is operated ..................... 42-65 Oil flow in the torque converter line ................................ 32-20 Oil flow to the clutches ................................................... 32-20 Oil port layout ................................................................. 32-24 Operation methods ........................................................... 42-5 Operation monitor lamps ................................................ 62-43 Operation of T.P.D ......................................................... 22-17 Orbit rotor operation principle ......................................... 42-66 Orbitrol® .......................................................................... 42-59 Orbitrol® specification .................................................... 42-60 Orbitrol® feed-back mechanism operation ...................... 42-63 Orbitrol® operation .......................................................... 42-61 Orbitrol® structure ........................................................... 42-59 Outline .............................................................................. 00-4 Outline of MODM (Machine Operation Diagnostic Module) Operation ................................... 92-59 Overload relief valve and make-up valve ....................... 42-68 Overload relief valve operation ....................................... 42-34

P Parameter change .......................................................... 62-85 Parameter Setting Monitor ............................................. 62-77 Parameter setting monitor display .................................. 62-77 Parking Brake ........................................................ 52-17, 53-8 Parking brake ........................................................ 52-2, 62-38

Parking brake clearance adjustment ................................53-9 Parking Brake Manual Release ......................................52-20 Parking brake operation ..................................................52-18 Parking brake performance check ....................................53-8 Parking brake solenoid valve ..........................................52-19 Parking Brake Spring Chamber ......................................52-22 Parts to be replaced periodically .....................................73-10 Pilot Valve (TH40MS) .....................................................42-25 Pilot valve operation .......................................................42-28 Pilot valve performance chart .........................................42-26 Pilot valve specifications .................................................42-26 Pin locations ...................................................................72-18 Plug in interface ..............................................................72-15 Power flow path ................................................................32-2 Power Flow Path in the Transmission ............................32-13 Power Generating/Charging Circuit ................................62-16 Power Line ........................................................................22-2 Preparation mode (ride control switch is OFF) ...............42-45 Preset height adjustment ................................................62-98 Pressure control valve ......................................................42-5 Pressure relief valve .......................................................72-73 Pressure sensor (for Declutch) ................ 52-24, 52-25, 52-26 Pressure Sensor (for stop lamp and declutch) ...............52-24 Pressure sensor (for stop lamp) .....................................52-24 Pressure switch ..............................................................72-12 Pressure switches ...........................................................72-71 Pressure temperature chart ............................................72-29 Principle of cooling ..........................................................72-43 Priority Valve ...................................................................42-55 Priority valve operation ...................................................42-56 Propeller Shaft ........................................................ 22-6, 23-3 Propeller shaft phase ........................................................23-3 Proximity switch ..............................................................62-93 Pump specifications ..........................................................32-3 Pumps & motors ...............................................................42-4 Purpose of flushing ...........................................................42-2

Q Q/Amp. ............................................................................42-59

R Radiator ............................................................................22-4 Radiator mount .................................................................22-5 Rear Chassis ....................................................................12-5 Receiver / Drier .................................................................72-9 Receiver dryer .................................................... 72-69, 73-10 Recommended Lubricants ................................................00-8 Recommended mixture of antifreeze ..............................00-10 Reducing Valve (for Pilot Pressure) ................................42-24 Refrigerant ......................................................................72-44 Refrigerant characteristics ..............................................72-45 Refrigerant charging procedure ......................................72-82 Refrigerant charging tools ...............................................72-79 Refrigerant hose .............................................................72-75 Relay A ...........................................................................72-74 Relay B ...........................................................................72-74 Replacement interval pop-up ..........................................62-65 Replacement interval set (timer reset) ............................62-64 Replacement Monitor ......................................................62-60

Replacement time check ................................................62-60 Resistance check mode ................................................62-101 Return oil from cooler .....................................................32-20 Return oil from torque converter .....................................32-20 Reverse 1st speed power flow path ................................32-17 Reverse 2nd, 3rd, and 4th speeds power flow path .......32-17 Reversing fan control chart .............................................42-91 Reversing fan motor .......................................................42-90 Reversing fan motor function ..........................................42-90 Reversing Fan Motor Line ..............................................42-90 Ride Control (OPT) .........................................................42-43 Ride control circuit reducing valve setting pressures (OPT) ............................................................................43-6 Ride control function .......................................................42-44 Ride control hydraulic circuit ...........................................42-44 Ride control operation .....................................................42-45 Ride control system (OPT) ...............................................42-9 Ride control valve assembly ...........................................42-47 Right brake pedal (brake only pedal) ..............................62-36 Rotor part ........................................................................42-60 Running mode (ride control switch is ON) ......................42-46

S Safety precautions ............................................................00-2 Safety relay .....................................................................62-15 Safety valve (with suction function) ................................42-83 Screw lock agent application procedure .........................00-19 Second propeller shaft alignment .....................................23-3 Second propeller shaft assembly ......................................22-7 Secondary Steering (OPT) .............................................42-93 Secondary steering (OPT) ................................................42-9 Secondary steering function (OPT) ................................62-41 Secondary steering motor and pump ..............................42-95 Secondary steering operation .........................................42-94 Selection of machine fault log and engine fault log ........62-67 Sensor assy ....................................................................62-96 Sensor Mount ...................................................................62-5 Service Brake ....................................................... 52-14, 53-6 Service brake ....................................................................52-2 Service brake friction plate .............................................52-15 Service brake friction plate wear measurement ................53-7 Service brake operation ..................................................52-14 Service brake performance check ....................................53-6 Service brake steel plate ................................................52-15 Shift lever forward/reverse (F/R) position .......................62-10 Shift lever neutral (N) position ........................................62-10 Shift lever position ............................................................32-4 Sight glass ......................................................................72-71 Solenoid valve ................................................................42-50 Solenoid valve operation ................................................52-19 Solenoid valve specifications ..........................................52-19 Specification Setting Monitor ..........................................62-86 Specification setting monitor display ...............................62-86 Standard Measurement Values for Performance Check ......................................................................................03-3 Starter switch ..................................................................62-11 Steering circuit relief valve setting pressures ...................43-8 Steering cylinder .............................................................42-21 Steering speed and flow rate control ..............................42-64 Steering System .............................................................42-53

Steering system ................................................................ 42-8 Surge voltage and surge suppression diodes .............. 62-102 Switching from automatic to manual .............................. 62-34 Symbols ............................................................................ 00-3

T T/C and T/M Oil Circulation ............................................ 32-21 Table 1: Abbreviations .................................................... 72-35 Table 2: General air conditioning system operating parameters ................................................................. 72-36 Temperature ranges ....................................................... 72-31 Temperature scales ........................................................ 72-30 The operation condition of ELS ...................................... 42-72 Thermostatic expansion valve .......................................... 72-8 Third propeller shaft assembly ......................................... 22-8 Tightening torque ............................................................. 23-4 To forward and reverse clutches .................................... 32-20 To speed clutches .......................................................... 32-20 Torque Converter ............................................................. 32-2 Torque Converter and Transmission ................................ 92-4 Torque Converter Gear Pump .......................................... 32-3 Torque Converter structure .............................................. 32-2 Torque multiplication ........................................................ 32-2 Transmission .................................................................... 32-4 Transmission – Rear differential ....................................... 22-8 Transmission Control Circuit and Monitor Circuit ........... 62-24 Troubleshooting using the gauge manifold .................... 72-88 Turn ................................................................................ 42-62

U Unit conversion and language selection ......................... 62-59 Unloader Valve ................................................................. 52-4 Unloader valve operation ................................................. 52-5 Unloader valve setting pressure ....................................... 53-2 Unloader valve setting pressure measurement ................ 53-3 Upper center pin ............................................................... 12-8

V Valve location ................................................................... 32-6 Valve part ....................................................................... 42-60 Valve System ................................................................. 42-59 Valve Unit ......................................................................... 52-6 Viscous mount .................................................................. 12-7

W Water valve actuator check ............................................ 72-25 Way of looking at connectors ......................................... 92-23 Weight of main components ........................................... 00-12 What do you know about temperature? ......................... 72-29 What is temperature? ..................................................... 72-31 When the compressor is replaced .................................... 73-3 When the condenser is replaced ...................................... 73-4 When the evaporator is replaced ..................................... 73-4 When the shift lever is moved (1) (Initial oil feeding to clutch piston chamber) ........................................... 32-27 When the shift lever is moved (2) (clutch oil pressure increase) .................................................................... 32-28 While the ELS is not operating ....................................... 42-76

While the ELS is operating ............................................. 42-77 While the valve is not operating ..................................... 52-12 Work procedure .............................................................. 72-77

MEMO

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes

65ZV-2 US 92-1 92 Drawing & Diagrams

92 Drawing & Diagrams Axle Assembly ......................................................................................................................... 92-2 Torque Converter and Transmission........................................................................................ 92-4 Hydraulic & Brake Circuit......................................................................................................... 92-5 Brake Circuit ............................................................................................................................ 92-6 Electrical Wiring Diagram (1/4) (S/N 5001~5050) ................................................................... 92-7 Electrical Wiring Diagram (2/4) (S/N 5001~5050) ................................................................... 92-8 Electrical Wiring Diagram (3/4) (S/N 5001~5050) ................................................................... 92-9 Electrical Wiring Diagram (4/4) (S/N 5001~5050) ................................................................. 92-10 Electrical Wiring Diagram (1/4) (S/N 5051~5100) ..................................................................92-11 Electrical Wiring Diagram (2/4) (S/N 5051~5100) ................................................................. 92-12 Electrical Wiring Diagram (3/4) (S/N 5051~5100) ................................................................. 92-13 Electrical Wiring Diagram (4/4) (S/N 5051~5100) ................................................................. 92-14 Electrical Wiring Diagram (1/4) (S/N 5101~5400) ................................................................. 92-15 Electrical Wiring Diagram (2/4) (S/N 5101~5400) ................................................................. 92-16 Electrical Wiring Diagram (3/4) (S/N 5101~5400) ................................................................. 92-17 Electrical Wiring Diagram (4/4) (S/N 5101~5400) ................................................................. 92-18 Electrical Wiring Diagram (1/4) (S/N 5401~) ......................................................................... 92-19 Electrical Wiring Diagram (2/4) (S/N 5401~) ......................................................................... 92-20 Electrical Wiring Diagram (3/4) (S/N 5401~) ......................................................................... 92-21 Electrical Wiring Diagram (4/4) (S/N 5401~) ......................................................................... 92-22 Electrical Wiring Diagram ...................................................................................................... 92-23 Electrical wiring diagram abbreviation chart .......................................................................... 92-25 Electrical Wiring Diagram (CAB) ........................................................................................... 92-27 Electrical Connection Diagram (1/2) (S/N 5001~5050) ......................................................... 92-30 Electrical Connection Diagram (2/2) (S/N 5001~5050) ......................................................... 92-31 Electrical Connection Diagram (1/2) (S/N 5051~5100) ......................................................... 92-32 Electrical Connection Diagram (2/2) (S/N 5051~5100) ......................................................... 92-33 Electrical Connection Diagram (1/2) (S/N 5101~5400) ......................................................... 92-34 Electrical Connection Diagram (2/2) (S/N 5101~5400) ......................................................... 92-35 Electrical Connection Diagram (1/2) (S/N 5401~) ................................................................. 92-36 Electrical Connection Diagram (2/2) (S/N 5401~) ................................................................. 92-37 Electrical Connection (Cabin Air Conditioner) (S/N 5001~5050)........................................... 92-38 Electrical Wiring Diagram (Cabin Air Conditioner) (S/N 5051~) ............................................ 92-39 Electrical Circuit Diagram (Cabin Air Conditioner) (S/N 5051~) ............................................ 92-40 Equipment Operation Table (Cabin Air Conditioner) (S/N 5051~) ......................................... 92-41 Electrical Equipment Layout .................................................................................................. 92-42 Front chassis .................................................................................................................... 92-42 Rear chassis (S/N 5001~5050) ........................................................................................ 92-44 Floor board (S/N 5001~5050)........................................................................................... 92-53 Outline of MODM (Machine Operation Diagnostic Module) Operation.................................. 92-59 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ......................... 92-68

65ZV-2 US 92-2 92 Drawing & Diagrams Axle Assembly

Axle Assembly Front axle assembly

(S/N 5101~5272)

(S/N 5273~)

(S/N ~5272)

(S/N 5101~)

1. Differential assembly 2. Axle housing 3. Axle housing 4. Internal gear 5. Spider 6. Axle shaft 7. Piston 8. Sun gear 9. Planetary gear 10. Separation disc 11. Pin 12. Friction disc 13. Taper roller bearing 14. Taper roller bearing 15. Straight pin 16. Spring pin 17. Plane washer 18. Shim 19. O-ring 20. O-ring 21. Brake backing plate 22. Wear ring 23. Needle cage 24. Oil seal 25. Plug 26. Seal washer

(S/N 5427~)

(S/N 5273~)

65ZV-2 US 92-3 92 Drawing & Diagrams Axle Assembly Rear axle assembly

(S/N 5101~5272)

(S/N 5273~)

(S/N ~5272)

(S/N 5273~)

(S/N ~5272)

(S/N 5273~)

(S/N 5101~)

(S/N 5427~)

65ZV-2 US 92-4 92 Drawing & Diagrams Torque Converter and Transmission

Torque Converter and Transmission (Model: Kawasaki CT140V03) 10

2 7

50T

Main pump installation

55T

24 23

17 21

28T 29T

28T 37T

57T

2nd

1st

43T

26T

Idler shaft

33T 43T

47T

37T

30 34

23T

38T

3rd 33T

4th

62T

26 25 29

65V2E92002

1. Pump impeller 2. Turbine impeller 3. Stator 4. Turbine shaft 5. Stator shaft 6. Flexible plate 7. Drive cover 8. PTO drive gear 9. T/C pump drive gear 10. Hydraulic pump drive gear 11. T/C pump 12. Reverse clutch 13. Reverse clutch gear 14. Forward clutch 15. Forward clutch gear 16. Counter gear A 17. 2nd speed clutch 18. 2nd speed clutch gear 19. 1st speed clutch 20. 1st speed clutch gear (Helical) 21. Counter gear B 22. Counter shaft A 23. Idler shaft 24. Idler 25. 4th speed clutch 26. 4th speed clutch gear 27. 3rd speed clutch 28. 3rd speed clutch gear 29. Counter gear C 30. Counter shaft B 31. Counter gear D (Helical) 32. Counter gear E (Helical) 33. Output shaft 34. Output shaft gear (Helical) 35. Parking brake 36. — 37. Suction strainer

65ZV-2 US 92-5 92 Drawing & Diagrams Hydraulic & Brake Circuit

Hydraulic & Brake Circuit

.+, 152

%&'(

% $

1 152

3 * 1

+, ,- + ,. /0 -123 ,1+4

* 1

> 6) 1,3. ) ;1 < %

;8 < $

;1 < %&'(

;8 <

"..23+7 91+

; ( ?<

)

3. 3,/ .+, .2 92.= 1, 3+

!. 61 43+7 8 14 "

)

! " !

) )

15 6 - @ ) 1 ; A 6 3<

"161 3,/

; 712< 1-7 +, ; ) 712<

:/0) .32 ..2 ;3+ . 6. 1, 0 3+ 1031,. <

:/0) .32 ,1+4

1. Hydraulic pump Front..........Steering Center........Loading Rear...........Brake and Pilot 2. — 3. Multiple control valve (loading circuit) 4. — 5. Boom cylinders 6. Bucket cylinder 7. — 8. Steering cylinders 9. — 10. — 11. Check valve (oil cooler bypass) 12. Return filter 13. Relief valve (return filter bypass) 14. Orbitrol® 15. Priority valve 16. Pilot valve (for loading) 17. — 18. — 19. Adapter (orifice, slow spool return) 20. — 21. Breather valve (oil filling port) 22. Unloader valve 23. Brake valve 24. — 25. — 26. — 27. — 28. — 29. — 30. — 31. — 32. Check valve 33. Accumulator (for brake) 34. Accumulator (for steering) 35. Solenoid valve (for parking brake) 36. — 37. — 38. Reducing valve (pilot, parking brake) 39. Line filter 40. — 41. — 42. — 43. — 44. — 45. — 46. — 47. — 48. —

49. Pressure sensor (for brake oil pressure) (for secondary steering) 50. — 51. Pressure sensor (for declutch & stop lamp) 52. — 53. — 54. — 55. Oil cylinder (for parking) 56. — 57. — 58. — 59. — 60. Pressure sensor (for ELS & new ECO mode) 61. — 62. — 63. — 64. — 65. — 66. — 67. — 68. — 69. — 70. — 71. Fan motor 72. — 73. — 74. — 75. — 76. — 77. — 78. — 79. — 80. — 81. — 82. — 83. Suction strainer 84. — 85. — 86. — 87. — 88. — 89. — 90. — 91. Motor and pump (OPT) (for secondary steering) 92. Check valve (OPT) 93. Check valve 94. — 95. Valve (for safety lock)

65ZV-2 US 92-6 92 Drawing & Diagrams Brake Circuit

Brake Circuit

!# '+(

'! '+(

! "! # $%&!"'() ' *

!#/ ,)(# 0'(0 # ,)(# 0'(0

!#/ 5' /# #!

# ,'!*) - .!'*

# 5' /# #!

/ ! 0

/ ! 0 / ! 0

!)#!) % # !#( 5(#6 !' 4 /)

!#/ 5' /# #!

!#/ /"( ),( # !#( 0'(0 7 ,!)#!) % 0'(0

# /"( ),( # !#( 0'(0

# ,!)#!) % 0'(0

',' ) %

4 2 -'(3 '"- ! 4 2 -'(3

1%& #)( ' *

1%& #)( ##( ! 2) #!,#!' & ) !'&)' #!3

1. Hydraulic pump Front..........Steering Center........Loading Rear...........Brake and Pilot 2. — 3. — 4. — 5. — 6. — 7. — 8. — 9. — 10. — 11. Check valve (oil cooler bypass) 12. Return filter 13. — 14. — 15. — 16. — 17. — 18. — 19. — 20. — 21. Breather valve (oil filling port) 22. Unloader valve 23. Brake valve 24. — 25. — 26. — 27. — 28. — 29. — 30. — 31. — 32. Check valve 33. Accumulator (for brake) 34. Accumulator (for steering) 35. Solenoid valve (for parking brake) 36. — 37. — 38. Reducing valve (pilot, parking brake) 39. Line filter 40. — 41. — 42. — 43. — 44. — 45. — 46. — 47. —

48. — 49. Pressure sensor (for brake oil pressure) (for secondary steering) 50. — 51. Pressure sensor (for declutch & stop lamp) 52. — 53. — 54. — 55. Oil cylinder (for parking) 56. — 57. — 58. — 59. — 60. — 61. — 62. — 63. — 64. — 65. — 66. — 67. — 68. — 69. — 70. — 71. — 72. — 73. — 74. — 75. — 76. — 77. — 78. — 79. — 80. — 81. — 82. — 83. Suction strainer 84. — 85. — 86. — 87. — 88. — 89. — 90. — 91. — 92. — 93. — 94. — 95. —

65ZV-2 US 92-7 92 Drawing & Diagrams Electrical Wiring Diagram (1/4) (S/N 5001~5050)

Electrical Wiring Diagram (1/4) (S/N 5001~5050) FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM (ELS) (OPT)

(+)

8 Lg D103 013 GyW S823 200

Lg D103 013 GL S822 265

PARKING S/W

B 4

HORN S/W

LR LBr B S911 S904 126 128 LW B S912 120 LY LG LO S910 S903 S905 121 122 123

6 L LgG D206 H137 005-b 162 GO SbW B S901 A712 164 163 3 1

RB A611 300

P RBr RO RW G703 A103 A106 F401 320 322 321 304

BW F005 271

D609 H712

DECLUTCH SENSOR

165 S921

LP F001 168

F/R S/W SELECTION 8

R RGy D109 002 R RGy D109 A801 002 310

311 521 C302 H106 4

BUCKET LEVELER/ FORK POSITIONER SELECTION (FOR 65TMV2)

312 520 C306 H138

YV S918 231 1

(2/4)

FUEL PUMP RELAY

BUZZER RELAY

HI-BEAM RELAY

HEAD LAMP RELAY

6 RW R H108 D108 308 001 RY RY RW F504 B912 305 304

3 A813 H118 306 307

Lg Lg D103 D103 013 013 LgSb LgBr G601 S609 112 104 1

WB YL D106 T805 011 715 BrL B H130 711 1

Lg Lg D103 D103 013 013 BG BR A802 W411 720 726

LgY F002 167 YO F003 176

WIDTH LAMP RELAY

(BLACK)

C305 H129 300 4 303

S3R S709

168 T606 B LP 271 167 T706 T608 BW LgY 255 176 T708 T601 BrG YO BrG YO S922 B001 255 176 BW LgY S813 A803 271 167 B LP S915 168

R R D108 D108 001 001 RB RB B914 301

BrW W604 G 252 H902 BrW H802 253 W602 250

NEUTRAL RELAY

MCU FAULT RELAY

HORN RELAY

LIFT KICKOUT RELAY

(BLACK)

2 4

3 2 3

G L D102 D205 014 005-a RL SbP H110 S618 703 145

G G D107 D107 010 010 GW GL H127 B801 329 328 1

LgW L A508 D205 102 005-a B LgW S612 101

2 BrR L G202 D205 272 005-a B L S610 273

BrB L G402 D205 257 005-a B BrB S611 258 1

B 3

G H116 036

5 YL

(BLACK)

(BLUE)

(BLACK)

(BLUE)

YB 716

715 F202 W402 W405

(BLACK)

PILOT VALVE MAGNETS (FOR 65TMV2)

TOOL CONNECTOR

MEMORY CLEAR

AIR-SUS. 8

S2H YL C201 W438 747 S2L C202

2 W R B303 B302 802 801 G L B304 B301 804 803

OY D114 007

T4 H1

SHIFT HOLD S/W (OPT)

YO W432 748

YSb S917 125

Br H801 003

KICKOUT

Br D110 003

(BLUE) Br

BrW

BrB

B 1

B (3/4)

HAZARD

LgSb X504 112

G D107 010

BrR

P R B909 D111 320 004 B

A101 A108 BP 323

G D107 010 B

5 1

1 5

1 767 172 003 603 100 W472 S722 D110 H906 S709 GL V GyL SbY Br 768 171 251 604 015 W460 S730 S826 H907 D101 GO WR BP SbY BrR 250 261 267 G302 S504 S501 BrW LgL GB 182 722 221 266 S806 W410 V303 S801 LgL BrG LgB GyB 35 31

W5113 W5105

910 D301 R 911 D402 R

1 912 D401 R 913 D901 R

914 D002 R 915 D001 R

901 E201 W

G Br W703 253 003

1 W601 W603

6 764 798 779 778 777 W474 W592 W593 W594 GW GyR YL YR YW 799 794 791 790 789 W597 W5121 W5110 W5103 W5111 W589 GyB RG YL YR YW 605 797 181 220 160 H908 W5116 S811 S723 S716 WY RG BrY GyO Y 793 796 795 792 159 W5117 W5120 W5118 W5119 S708 LgW LgY LgR LgBr Y 36 40 10

141 S518 LY B 142 148 S502 S604 LG LBr 143 146 S505 S613 LO LR 3

FLOAT

TURN SIGNAL

(BLUE) 1

POSITIO -NER

Br H801 003 3 (BLUE)

2 2

3 3

1 226 V404 LgB 221 V403 LgB

W421 W440

CAB ALARM BUZZER

DOWNSHIFT BUTTON

G BrW BrW W703 W702 W701 253 252 250

LgB V303 221 LgB V304 226

LgB H132 221 LgB S702 226

1A 1 3

BrG W452 738

FUSE

1 3

LOWER KICKOUT RELAY

BrW W807 G 252 W806 253 BrW W808 250

ECM MAIN RELAY

S3W S818

S3B S707

6 703 325 308 404 311 F704 A107 F404 A614 B108 RL RO RW YBr RLg 114 327 306 036 S707 A102 F403 T803 BY RBr RY G 711 303 330 329 180 F204 F604 S510 F804 S731 GW GyL BrL RB RL 707 331 312 162 S724 S619 B208 B506 WL RG RGy LgG 40 36

1 3 4 6

R R D108 D108 001 001 RY RY F402 B915 305 302

1 3 4 6

AIR TEMP. PROBE (MCU)

R G B O Y V

V BY S709 S707 100 114 LgR S727 166

RG RLg D113 006 RG RGy D113 A801 006 310 1

B101 B201 310

GLOW LAMP RELAY

THROTTLE PEDAL

2 +

−

WL S624 400

LLg

S729 T406 W418

RY RBr RO F403 A102 A107 307 326 324 LgY BG RGy F002 F104 167 720

S2L S2H

S720 T414 W437

RGy RB G WBr RLg O B208 D107 D604 B108 D610 520 300 010 022 521 020 PB PL OR OL H722 H732 D608 500 506 019 018

BY G S707 S732 114 415

Y E401 531

176 F003

S2S

DECLUTCH SET-UP

BrG F004 255

CAB

GyB S514 103 LgR S521 130

A611 F604

RB RY F601 F501 301 302

DECLUTCH CUT-OFF S/W

TC H

CAN (RESISTOR)

1 3 4 6

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET UP

1 804 803 C804 C801 L G 802 801 C803 C802 W R

(ZV: S/N 5015~) (TMV: S/N 4011~)

GND

DIODE UNIT

COMBINATION S/W FOR LAMPS

F801

G Y B

328 GL

A0 WG A503 705 WL S724 707

1 6

3 GW

SHIFT LEVER

12 B LY LG LO LW SbW S518 S502 S505 S508 B502 141 142 143 144 163 Lg GR D103 S529 013 135

20 7

RB YBr H107 300 404 Lg BrW BrR LgB YB BrW O RL W407 W406 S524 S734 S721 D103 S512 S532 013 241 235 732 730 224 401 402 1

GyG Gy LgY LgW S515 W417 S528 F903 753 749 173 102 WG LgW GyL A001 S527 S516 705 192 190

−

272 T003 BrR

+ GND

257 T903 BrB

WTM TTM

1 3 4 6

2 5

250 H123 BrW

BrW W702 252

EG2 EG1 EG3

BrW W701 250

8 RO RO BP B911 G803 321 323 RBr RBr BP B910 G803 322 323 A814 1 H119 A1 326 327

124 S914

324 325 A815 H109

C EP

GND

REAR WORKING LAMP

1 3 4 6

INSTRUMENT PANEL

B601 C305

YSb S506 403

FUEL EFFICIENT MODE SELECTION

HAZARD

YG D702 025 GL H102 603 GO H112 604 WY H730 605

YG D702 025 W D804 029 W D804 029 LR D804 029

TO AIRCON

1 1 771 772 773 769 W587 W480 W467 W479 W583 S4R VR Gy BG GR W590 770 019 774 W5101 W582 W584 C309 W595 S4B S4W GyR OR VR 500 775 W5100 W598 W599 C307 W591 GB S4S/S5S S5B S5W PB 506 776 W5108 W5106 W5107 C308 W5109 BLg S6S S6B S6W PL 35 31 5

This page illustrates the transmission is in neutral and key switch is in OFF position. 65ZV2/TMV2-09709-09461 USA 1/4 65V2U92001

65ZV-2 US 92-8 92 Drawing & Diagrams Electrical Wiring Diagram (2/4) (S/N 5001~5050)

Electrical Wiring Diagram (2/4) (S/N 5001~5050) MCU A 1.2S_SO A 2.2_SO A 3.ES_R A 4.DD_SO A 5.3_SO A 6.HM A 7.LU_SO A 8.4_SO A 9.EG_SW1 A10.R_L A11.F_L A12.ST_L A13.WL_L A14.CW_L A15.ET_L

A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.SS_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

A31.1/4_L A32.FR_L A33.3/4_L A34.EG_SW3 B 1.H_SO B 2. B 3.IP_SO B 4.R_SO B 5.MO_SO B 6.FR_SO B 7.SSL_SO B 8.ISW_R B 9.BZ B10.BSL_R B11.KO_R

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

A27

A28

A29

A30

A31

A32

A33

A34

Note: See Section 62 for details.

ODOMETER SELECTION

A/M SELECTION

PB S916 110

PG S902 109 1

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B21

B22

B23

B24

E 1.SSR_SO E 2.FC_SO E 3.KEY E 4.KEY E 5.GND E 6.GND E 7.GND E 8.GND E 9.+5V E10.TGEG E11.KEY E12.KEY E13.CANH1 E14.EGR2 E15.EGR1

B25

B26

YB GR WL GyG YO T103 S203 A806 T301 S205 811 115 400 754 118 GL YBr SbP RG T104 S201 F701 H139 810 119 145 331 L LgBr BrB LgW LR X501 T001 T901 F901 H204 104 273 258 101 146 LBr LgL H205 E502 148 225

E701 H128

A709 H202

26 (S/N 5009~, 4003~)

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E27

E28

E29

E30

E31

E32

C 1.2S_SE C 2.POD_SW1 C 3.POD_SW2 C 4.DSUB4 C 5.TT C 6.AC C 7.ET C 8.BL C 9.BD C10.DSUB1 C11.HYDOL C12.DR C13.BSL_S C14.TF C15.WL

E11

E33

C16.EP C17.F C18.ASUB1 C19.TEMP_SE C20.1/2 C21.1/8 C22.2S C23.EGM C24.IP_SW C25.FR C26.KO_P C27.ES_SE C28.3/4 C29.1/4 C30.DC

C31.BSL C32.DSUB3 C33.DD_S C34.AFR D 1.PRK D 2.AM_SW D 3.SL_2 D 4.SL_R D 5.SL_3 D 6.S_UP D 7.S_DOWN D 8.EG_SW D 9.M_SW D10.SL_1 D11.SL_F

C10

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C26

E34

C27

C28

C29

C30

C31

C32

C33

C34

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D21

D22

D23

D24

D25

BrR SbR H113 E802 251 240 S3W C001

707 A002 H140 100 C702 C003 E803 H101 T101 W103

GyB H131 266 1

Y B T202 105 GL GyW A302 A202 265 200 BW BrY R H728 T203 F005 181 106 271 LgL H135 182

LLg BrG YW LB B002 F004 E012 E006 165 255 233 230 YL LP PB YSb YV YO G101 F001 S301 G901 A401 E005 124 168 110 125 231 232 LR LY LW B B703 B709 B706 121 126 120 GO PG LG LBr LO B503 S401 B702 B708 B701 164 109 122 128 123 1

114 C701 C002 T302 C902 H120 E801 T102

S9 T1

FUSE BOX (MAIN)

003 G201 G301 G401 H103

BW BG

R1 S2L B R2

WRx2

ACC

WBx2

W3 W5

STARTER SWITCH

WR WR D501 D503 063 065 BW D504 062

RG LR LW YR YW

R G702 004

002 WB F203 011

006 G F703 014

R H301 910

R H302 911 R H401 912

WR O

14 OY T501 007 WR

4 L

H111 W424

015

B202 B207

A207 A307 A610 A706 E601 F102 F103 X502 X503 013

FUSE BOX (CAB)

B102 B107

D505 D506 060 061

W H601 901

G D502 064

7 C304 F802 F803 G501 G802 S717 010

W 001 8 R F406 F502 F503 F602 G F603

STARTER S/W

YB YG YBr S623 S733 S617 115 116 119 YL B YO S725 S626 117 118

3 4 5 1 6 2 L L L L L L S703 S704 S711 S712 F702 B504 005-A 005-B 005-C 005-D F902 005-b T902 T002 005-a

WR RL

OL OR O C310 C309 C301 018 019 020

H904 H905

WBr R E302 C303 021 022

BY GyG S707 S625 114 754

RS232C

E/G WATER TEMP. SENSOR (FOR INSPECTION)

(ZV: S/N 5009~) (TMV: S/N 4003~)

R Y S812 S830 106 105

DIAG. S/W CONNECTION

025

1 4 H901 H902 D7 H903 029

Note: These switches/connectors are for factory use only.

R H402 913

R H501 914 R H502 915

W/LR

GL V S616 S709 810 100 GR BY S622 S707 811 114

MCU PROGRAM REWRITE (NOT USED)

6 BW W W E104 E202 E202 062 061 060 WR G WR E107 E101 E106 065 064 063

(ZV: S/N 5009~) (TMV: S/N 4003~)

D26

GyW LgY E603 E501 260 223 Lg E503 222 B

D20

D12.SL_A D13.DSUB2 D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

26 YG YB S2H SbY GyL G C201 H114 H126 C901 S202 A603 171 180 415 116 401 YL S2L BrW SbY GyO WL S204 C202 A602 H104 H727 117 402 172 220 L L W G Y D203 D204 W101 H726 D107 005-C 005-D 161 160 010 LgB L L B B BY/S3B Y V/S3R V304 D201 D202 H736 226 005-A 005-B 159

LgR C703 166

A710 H203

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E10

E26

A708 H201

E16.SPD E17.BATT E18.CANL1 E19.SS_P E20.CANLO E21.TM_M E22.B_SE2 E23.WT_SE E24.ALT E25.RXD1 E26.TGSP E27.INCH_SE E28.ASUB2 E29.CANHO E30.B_SE1

LgW LgY GR RL A502 A507 A701 A608 192 173 135 235 LY LgR LgB A808 A604 130 224 141 RL GyB GyG GyL O A809 A505 A501 A609 241 103 753 190 330 GB LG YGy LgL LO YSb LW A901 H121 E804 H122 A711 267 142 242 261 143 403 144

(BLACK)

B2 B8

B20

Note: For factory use only.

B12.X_R B13.F_SO B14.B_SO B15.EG_SW2 B16.RIN1 B17.OUT_MD2 B18.N_R B19.BR_L B20.CAN_R1 B21.CAN_R2 B22.DOUT1 B23.OUT_FEW B24.MT B25.ET_SE B26.TXD1

1 4

DC-DC CONVERTOR

(ZV: S/N 5009~) (TMV: S/N 4003~) F/R SWITCH/ STICK STEERING

REVERSAL FAN S/W 3

YW S926 233

B 4

BACK LAMP

2 Lg LgL S825 S606 222 225 B LgY S834 223

YO LB S919 S924 232 230

GyW S833 260 Lg D103 013

B 1

EMERGENCY STEERING

RIDE CONTROL S/W

RL S510 330

YGy V S709 S503 100 242 SbR S827 240 BY S707 114

R D605 021

2 6

OUT

Y C102 531

This page illustrates the transmission is in neutral and key switch is in OFF position.

65ZV2/TMV2-09709-09461 USA 2/4 65V2U92002

65ZV-2 US 92-9 92 Drawing & Diagrams Electrical Wiring Diagram (3/4) (S/N 5001~5050)

Electrical Wiring Diagram (3/4) (S/N 5001~5050)

ECM

106 E106 E107 E108 E109 E110 E111 E112 E113 113

V24

V23

V22

V21

V20

V19

V18

V17

V16

V15

V14

V13

V12

V11

V10

V43

V42

V41

V40

V39

V38

V37

V36

V35

V34

V33

V32

V31

V30

V29

V28

V27

V26

V25 25

E98

E99

E100 E101 E102 E103 E104 E105 105

V62

V61

V60

V59

V58

V57

V56

V55

V54

V53

V52

V51

V50

V49

V48

V47

V46

V45

V44 44

E90

E91

E92

E93

E94

E95

E96

E97

V81

V80

V79

V78

V77

V76

V75

V74

V73

V72

V71

V70

V69

V68

V67

V66

V65

V64

V63 63

E82

E83

E84

E85

E86

E87

E88

E89

119

120

121

E119

E120

E121

E117

E118

E114

E115

E116

114

115

116

H115 W202 B W481 000

ATM. PRESS. SENSOR

−

YL T805 715

(ZV: S/N 5009~) (TMV: S/N 4003~) B

YL T805 715

GyL GL H105 W201 767 766 BrG T401 738

Gy H703 772

GyR S4W GR S4R H714 H701 H713 H705 770 769 YL S4W GB YR YW VR H714 H721 H708 H707 H706 H711 779 775 778 777 774

GyB H720 799 GyB H720 799

WR D101 015

YL S2L T407 C202 747 S2H Gy C201 A506 749

YB T801 716 YB T801 716

YO G001 748

S5B S5W S4S/S5S S4B H724 H723 H725 H715

GyR H709 105 798 GyR H709 113 798

25 BR BrG F101 H134 726 722

WY BrW BrR W102 A606 A605 758 732 730

YR 98 H717 790 S6B S6W S6S BLg YL YW 106 H734 H733 H735 H731 H718 H716 776 791 789

115

116 RG H729 797

89 97 LgW H740 793

VW BP GL W461 W460 W471 765 768 766 3

114 GW H710 764

B VR BG 81 W301 H704 H702 000 771 773 VW BP 62 W203 B 765 768

LgR H738 795

LgBr H737 792

LgY H739 796

RG H719 794

119

120

121

W1 W S715 161 1

V S709 100 WY W408 758

RESISTOR FOR E/G SPEED 2

This page illustrates the transmission is in neutral and key switch is in OFF position.

65ZV2/TMV2-09709-09461 USA 3/4 65V2U92003

65ZV-2 US 92-10 92 Drawing & Diagrams Electrical Wiring Diagram (4/4) (S/N 5001~5050)

Electrical Wiring Diagram (4/4) (S/N 5001~5050)

B LgL R801 R901

T/M OIL TEMP. SENSOR (MCU)

AIR CLEANER

702

* ) & &

R N502 701

& )

" 2

YBr H107 404

GyG BY H136 H120 754 114

& $ * & *

$ &

WL N901 H140

G M001 M002 W N101 086

" !

W N303 900

" ,+ * & & !

& &

1 012 720 N601 N602 R BG 015 708 N401 N402 WR WP B

DIODE UNIT

3 3

1 4 702 703 706 N702 N804 BW N701 RL WL 705 701 ! N801 N703 R WG B 3 2

R P002 701 BW P001 702

! 4

R BG H134 H124 012 720 1

WG N704 N903 704 705

,* ,& *

B WG H125 705 RL WL/WP H115 M701 703 P602

2 2

3 3

WY H730 24

303 R501 RB B 330 R301 R401 R201 RL RGy

! " " !

LgB BY H132 H120 221 114 1

RL RGy H128 H138 330 312 RB B H129 303

" "

ECM

& ! *

BACK UP ALARM

R104

303

)

LICENSE

LAMP

*)& &

" & −

(

LH BATTERY +

REAR WORKING LAMP

R501 " " R502 "

−

& ! *

LAMP

312

REAR WORKING

RGy R102

312

RGy R102

−

RH BATTERY

G G N002 N002 036 036

P803 P803 P804 P804 G G

2 1

221 114 P101 L702 LgB BY

2 1

B WL N901 706

4 1

4 2

! !

WG N801 704

N8 VOLTAGE RELAY

R N502 3 701

RL N904 703

! N7 MAGNETIC

W N102 900

! WR WP " H111 015 N901 708 6

" " " " " "

S/W

BW N501 702 2

G M001 M002 3

$ * & 2 *

$& &

BG P601 720

B WV N403 700 $ * &

R H301 H302 H401 H402 H501 H502 910915

G B M001 M002

LgB P501 221

& ! & & + &

% - . ' % - . '

FAN SPEED ) CONTROL SOL. VALVE

N3 BATTERY RELAY

* & + &

R P606 012

700 N301 WV 015 708 P605 P602 WR WP

! &

$ &&, ) + &

" ,+ * & + &

1 ! W H601 ! N001 901 086

LP H207 149

70A

N2 FUSIBLE LINK

FUSE

M7 ALTERNATOR

AIR HEATER

N1 FUSIBLE LINK

GyL BY H126 H120 180 114

30A

$ & & & &

LW H204 144

N6 HEATER RELAY

* & * & + &

$ &

FUEL LEVEL SENSOR

E/G WATER TEMP. SENSOR (MCU)

−

30A

LgL K204 261

LgL L401 261

(

*,& ) & *,

−

P0 BW STARTER * ) N501

LgL L401 261

L802 B 603 604 L803 L804 GL GO # 3 2

" −

AIRCON

LgL L806 182

RIDE CONTROL SOLENOID

(

" " " "

& ) * *

REAR % + "' COMBINATION LAMP (R.H) !

REAR ) * * COMBINATION (L.H) LAMP !

% + "'

& * & + % * ' 2

D −

BRAKE OIL PRESS. (MAIN)

− L0

−

S2L S2H P902 P901

(

−

(

−

S −

−

S2S P903

WR H720 015 GyR H721 751

LO B "J5 − + H203 143 2 1 "

1 2

L2 (

BY K203 114

251

V * K202 BrR 100 & *, K205

V L301 100 BrR L302 BY 251 114

L303

)

182 L002 LgL

(

S +

BY V H101 H120 100 114 SbY H104 172

L901 B

PARKING SOLENOID

! " "

& &

LgG BY V B H101 H120 " H137 " 162 100 114 SbY H114 " " " 171

V L201 100 BrR L203 251 BY L202 114

P746 P737 H709 S2H H707 P747 S2S H708 S2L

! " "

603 604 L902 L903 GL GO

" " "

B 1

GL GO H102 H112 603 604

" " "

5 1

! " "

" " " " " " " " "

1 BrG GyY H714 H734 738 736 SbY GyW H711 H724 209 737 PW PG BLg BrW H723 H733 H705 H725 740 739 735 733 Sb BL H704 H713 205 H717 BrB BrR GyR W H729 H739 H737 H731 731 730 752 161 45 41

LgL H135 182

−

LG H202 142

6 YV YL H706 H715 747 734 YO H716 748

(

SENSOR

) & BOOM ANGLE & & &

−

R K201 003 BrW B K206 250

$ * * &

BUCKET %$ 'LEVELER

K803

& *, &

! "

" H801

K802

CAN (RESISTOR)

# "

#! " P2

330 R103 RL

" H802

−

# # # " " " M4 " "

RB K106 327 RBr K103

K801

303

−

COMBINATION ) * * % * ' LAMP

K0 1

GyB " H131 266 BY V H120 H101 114 100

! " ! "

2 " " "

" "

Y Y H726 H736 160 159

+ LY H201 141

(BLUE)

4 " 4 " "

" "

" " " " L7

GB H121 267

LBr B J2 H206 148 , &&, 2 1 &

−

BY V R H120 H101 H103 114 100 003 LgL BrR BrW " H122 " H123 H113 261 251 250

−

GROUND SPEED SENSOR

% &'

PL H732 506

FRONT HEAD LAMP $ "& , (OUTSIDE) % *,&'

−

) & PB 3

BrY H728 181

−

(OPT)

Br GyO BY H727 P502 114 220

V BY L103 L201 L202 003 100 114 BrW BrR LgL L102 L203 L401 " 250 251 261

(

−

& *, &

−

! "& LR B J1 H205 146 % '

OR PB H722 H712 500 019

RO RB H109 H129 325 303 RL RG H128 H139 330 331 B

WORKING ! * LAMP (INSIDE) %* *,&'

311

" " WASHER MOTOR

EFFICIENT EFFICIENT ,* LOADING &$$*)*& & %& ' LOADING SYSTEM (ELS) SYSTEM (ELS) ,* * & + SOLENOID OIL PRESS. & %& ' & VALVE SENSOR

T/M SOLENOID VALVE

&$$*)*&

1 R

RLg K105

% * '

COMPRESSOR

GW K107 329

HYD. OIL LEVEL S/W

RBr RB H119 H129 327 303 RL RG H128 H139 330 331 B

GW B K701 K703

HYD. OIL TEMP. SENSOR

! N101 901

! "

2 2

GW K601 329

N201 915 R N201 914

" %"'HORN (H)

K105

N201 913 R N201 912

70A

RLg

311

RW RY K108 K102 308 306 B

" H8

N201 911 R N201 910

70A

40 36 35 31 ! #! # # # BrR GyR GyY PG PL W Y # & P701 P743 M901 P724 M803 P741 P742 730 752 159 736 739 506 161 ! 4 Y WY BrB GyO BrY ! BrW GyW PW PB GyR 1 P201 P744 L701 M902 M401 P722 P711 P725 M802 P749 605 731 181 220 160 733 737 740 500 751 141 142 143 144 J302 J402 J502 J602 ! OR SbY WR ! BL YO YV BrG BL LY LG LO LW P739 P720 P734 P709 P702 P734 M801 P713 015 741 748 734 738 741 019 209 149 148 146 J702 J202 J102 YL BLg Sb S2H S2L S2S ! ! B LR LP LBr P901 P902 P903 P710 P723 P731 5 8 735 205 747 10 6 1 5 H2

! * WORKING LAMP %* *,&' (INSIDE)

GW K601 329

RW RY K108 K102 308 306 B

! !

B RBr RY RO 311 303 329 308 H106 H129 H127 H108 RLg RB GW RW

$ "& , FRONT HEAD LAMP % *,&' (OUTSIDE)

(L) HORN

K503

" % '

K502

K101

1 " " " 1 327 " 306" 325 " " H119 H118 H109

K501

8 RLg RB GW RW K401 K501 K601 K303

LgL R WL RG RGy LgG GyG LgB GyB 303 K106 R605 P501 L603 L806 P606 M701 R102 M101 M601 R104 707 R705 182 012 221 266 312 162 754 R606 RB RL GW GyL WG BG BrW LgL GB R706 N903 P601 M501 K107 K206 K204 L501 705 720 329 261 180 250 267 R103 BY RBr RY RL SbY BrR GO WR M203 K102 L804 N904 K205 P605 R602 K103 ! R701 R702 306 604 703 251 015 171 RW YBr RLg GL V 330 RO SbY R M303 K201 K101 K108 J801 K105 L803 K203 L601 R601 308 404 311 603 003 172 M201 10 6 5 1 M301 K202 M502 M602 L602 P502 M202 114 M302 H1 100 "

K901 K801 329 K003 RBr RY RO B K802 K302 K502 327 K002 325

303 RB K106 325

LAMP

) * * % * ' COMBINATION

" & −

(

This page illustrates the transmission is in neutral and key switch is in OFF position. 70ZV2-09709-08491 USA 3/3 70V2U92015

65ZV-2 US 92-11 92 Drawing & Diagrams Electrical Wiring Diagram (1/4) (S/N 5051~5100)

Electrical Wiring Diagram (1/4) (S/N 5051~5100)

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM (ELS) (OPT) B601 C305

(+)

EG2 EG1 EG3

WTM TTM

+ GND

W GND

192

GyW S823

GL S822

013

241

730

224

401

402

143

B B 328

320

322

321

L D206

LgG H137

LR LBr S911 S904 6

4 005-b

164

121

RB A611

122

123

300

S729 T406 W418

300

500

506

PB PL H722 H732

010

019

D609 H712

BrG F004 255

LP F001 168

022

521

OL D608

020

S921

018

4 4

CAB (AIRCON) 4 Sb GO WR 6 H907 H908 H909 623

621

627

626

BrB LgY H912 H911

C802 H011

DECLUTCH SENSOR

6 WP LgR PL BR BL 10 C5 H910 H913 H015 H008 634

617

612

635

625

622

619

631

100

114

S3W S3B S3R S818 S707 S709

166

7 LO GW BY BrY Y RL 12 C6 H901 H902 H903 H904 C801 D701 615

611

616

026

WY V PB YB VW P H920 H919 H918 H917 H916 H914

614

AIR TEMP. PROBE (CONTROLLER)

C306 H138

BrG YO S922 B001 255 176 BW LgY S813 A803 271 167 B LP S915 168

WB YL D106 T805 011

715

Lg Lg D103 D103

BrL H130

LgSb LgBr G601 S609

013 726

802

OY D114

804

G H802

G W806

253

BrW W807

250

252

BrW W808 250

HORN RELAY

R D108

R R D108 D108

R R D108 D108 001

001

G L D102 D205

G G D107 D107

RY RY F402 B915

RB B914

RL SbP H110 S618

GW GL H127 B801

001

305

001

305

304

C305 H129

302

703

(BLACK)

010

145

329

(BLACK)

014 005-a

301

300 4 303

306 307

RY RW F504 B912

3 A813 H118

(BLACK)

308

RW H108

CONTROLLER FAULT RELAY

2 4

1 (BLACK)

ECM MAIN RELAY

LIFT KICKOUT RELAY

LOWER KICKOUT RELAY

LgW S612 101

257

005-a

BrB S611

272

005-a

L S610

036

YB 716

(BLUE)

715

F202 W402 W405

W421 W440

801

B YO W432

748

Br H801 003

125

YSb S917

KICK OUT

POSITIO -NER

T8 CAB ALARM BUZZER

PILOT VALVE MAGNETS

(FOR 65TMV2) SHIFT HOLD S/W (OPT)

2 2

LgB H132 221 LgB S702 226

(BLACK)

G H116

5 YL

1 1

3 3

B 3

273

(BLUE)

BrR L G202 D205

258

BrB L G402 D205

102 005-a

LgW L A508 D205

V4 226 V404 LgB 221 V403 LgB

3 3

LgB V303 221 LgB V304 226

1 3

328

(BLACK)

010

3 1

803

252

G L B304 B301

007

BrW W604

NEUTRAL RELAY

WIDTH LAMP RELAY

104

(BLACK)

W R B303 B302 B

G BrW BrW W703 W702 W701 253

HEAD LAMP RELAY

013

112

(BLACK)

013

711

FLOAT

TURN SIGNAL

3 (BLUE)

S2L C202

Hi-BEAM RELAY

BG BR A802 W411 720

LgY F002 167 YO F003 176

Lg Lg D103 D103

MEMORY CLEAR

AIR-SUS.

747

BUZZER RELAY

FUEL PUMP RELAY

DOWNSHIFT BUTTON

S2H YL C201 W438

O Y V

231

FUSE

1 168 T606 B LP 271 167 T706 T608 BW LgY 255 176 T708 T601 BrG YO

TOOL CONNECTOR

YV S918

310

R G B

738

629

415

630

114

632

BrG W452 BY G S707 S732

633

620

002

312 520

002

R RGy D109 A801

310

006

R RGy D109

311 521

C302 H106

RG RGy D113 A801

613

AIR PROBE (TH AM) (OPT)

RG RLg D113

250

THROTTLE PEDAL

LgR S727

WG OL BrW BG H014 H013 H012 H007

610

+ S

616

V BY S709 S707

612

628

BR Y C509 C611

624

B B

LLg

G WBr RLg O D107 D604 B108 D610

165

520

176

RGy B208

S2H

BrW W602

S2L

S720 T411 W437

1 F003

S2S

CAB

(2/4)

013

6 A611 F604

310

B101 1 B201

B403 B402 R W

801

BW F005 271

252

1 3 4 6

DECLUTCH CUT-OFF S/W

CAN(RESISTOR)

803

802

804

DECLUTCH SET-UP

1 3 4 6

006

GLOW LAMP RELAY

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET UP

DIODE UNIT

302

LY LG LO S910 S903 S905

163

128

301

120

162

GO SbW S901 A712

126

LW S912

RB RY F601 F501

B404 B401 G L

B8 R

304

F/R S/W SELECTION

16 P RBr RO RW G703 A103 A106 F401

F801

720

167

WG A503

707

400

324

LgY BG RGy F002 F104

WL S724 TL

326

705

PARKING S/W

Y E401 531

130

HORN S/W TB

307

WL S624

COMBINATION S/W FOR LAMPS

SHIFT LEVER

RY RBr RO F403 A102 A107

103

LgR S521

135

GyB S514

163

GR S529

144

013

732

142

141

Lg D103

BrW BrR LgB YB BrW W407 W406 S524 S734 S721

235

265

404

Lg O RL D103 S512 S532

190

013

200

326 327

Lg D103

013

323

A814 H119

705

YBr H107

300

102

250

322

Lg D103

173

252

BP G803

749

WG LgW GyL A001 S527 S516

Br H801

(BLUE) 1

Br D110 003

003

250

RBr RBr BP B910 G803 4

753

323

321

GyG Gy LgY LgW S515 W417 S528 F903

403

BrW W702

BrW W701

RO B911

124

7 8

S914

324 325

A815 H109

12 LY LG LO LW SbW S518 S502 S505 S508 B502

YSb S506

20 7

11 RB

(BLUE) Br

Br D110 003

112

010

BrW

BrB

BrR

P R B909 D111 004

A101 A108 BP 323

G D107

AIRCON UNIT

B 1

010

LgSb X504

G D107

320

B (3/4)

HAZARD

272

T003 BrR

257

T903 BrB

BUCKET/FORK POSITIONER SELECTION (FOR 65TMV2)

H123 BrW

1 2

REAR WORKING LAMP

INSTRUMENT PANEL

GND

FUEL EFFICIENT MODE SELECTION

HAZARD

610

613

615

611

620

633

632

630

629

029

028

642

643

C607 C608 C609 C610 LO GW BY BrY

624

623

621

628

614

634

627

626

631

635

C404 C405 C406 C506 Sb GO WR WP 026

C606 C605 C604 C603 C602 D701 C601 C507 C402 C401 WY V PB YB VW RL P LgR BrB LgY 11

1 10

F704 A107 F404 A614 B108 RL RO RW YBr RLg

003

642

100

W472 S722 D110 H003 S709 GyL SbY Br RW V

S518 LY

114

768

171

251

643

015

S502 S604 LG LBr

308

404

311

327

306

225

036

S707 A102 F403 S606 T803 BY RBr RY LgL G 711

303

330

329

707

331

312

180

162

250

261

722

S806 W410 LgL BrG 35

221

143

266

V303 S801 LgB GyB 31

W5113 W5105

148

910

D301 R

146

911

D402 R

D401 R 913

D901 R

1 912

914

D002 R 915

D001 R

901

E201 W

G W703 253

Br 003

1 W601 W603

W597 W589

798

D804 D802 H102 H112 R RB RW Y 027

6 764

S505 S613 LO LR

267

G302 S504 S501 BrW LgL GB 182

S724 S619 B208 B506 WL RG RGy LgG

142

W460 S730 S826 H004 D101 BP SbY BrR Y WR

F204 F604 V704 F804 S731 BrL RB RL GW GyL

172

325

141

767

703

779

778

777

W474 GW

GyR

W592 W593 W594 YL YR YW

799

794

791

790

789

W5121 W5110 W5103 W5111 GyB RG YL YR YW 641

797

181

220

160

793

796

795

792

159

H016 W5116 S811 S723 S716 YR Y RG BrY GyO W5117 W5120 W5118 W5119 S708 Y LgW LgY LgR LgBr 40 36

1 771

772

773

769

500

775

506

776

W587 W480 W467 W479 W583 S4R VR Gy BG GR 019 774 W590 770 W5101 W582 W584 C309 W595 S4B S4W GyR OR VR W5100 W598 W599 C307 W591 S4S/S5S S5B S5W PB GB W5108 W5106 W5107 C308 W5109 S6S S6B S6W PL BLg 35 31

026

641

617

C501 C510 BG BL 625

622

619

612

D803 D701 H730 C508 C504 C503 C502 C509 RG RL YR PL WG OL BrW BR 18

B B 10

This page illustrates the transmission is in neutral and key switch is in OFF position. 65ZV2/TMV2-09709-09700 US 1/4

K65V2U92009

65ZV-2 US 92-12 92 Drawing & Diagrams Electrical Wiring Diagram (2/4) (S/N 5051~5100)

Electrical Wiring Diagram (2/4) (S/N 5051~5100) MCU

A/M SELECTION

PB S916 110

PG S902 109

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A27

A28

A29

A30

A31

192

173

242

1 A709 H202

B13

B14

B15

B16

B17

B18

B19

B21

B22

B23

B24

B25

B26

811

115

754

400

L BrB LgW LR LgBr X501 T001 T901 F901 H204

753

190

YSb A901

143

104

144

403

145

101

258

148

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E27

E28

E29

E30

E31

E32

171

331

180

172

402

L L D203 D204

226

161

160

005-A 005-B

159

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C27

C28

C29

C30

C31

C32

B Y T202 105 GL GyW A302 A202

240

265

181

106

C33

C34

D11

D12

D13

D14

D15

D16

D17

D18

D19

D21

D22

D23

LLg BrG B002 F004 165

D24

D25

YW E012

LB E006 230

255

D26

233

YL LP PB YSb YV YO G101 F001 S301 G901 A401 E005

222

124

168

110

LR LY LW B703 B709 B706

121

125 126

231

232

120

GO PG LG LBr LO B503 S401 B702 B708 B701

182

164

C701 C002 T302 C902 H120 E801 T102

D10

223

LgL H135

266

D20

Lg F007

200

GyW LgY E603 F008 260

271

GyB H131

C702 C003 E803 H101 9 T101 W103

C15

BW BrY R H728 T201 F005

100

C14

010

BY/ Y V/ S3B H736 S3R

114

A002 H140

C13

S3W C001

707

C12

251

117

220

C11

BrR SbR H113 E802

401

YL S204

116

415

C10

C26

E34

W Y G W101 H726 D107

005-C 005-D

LgB L L V304 D201 D202

225

E33

S2H SbY GyL G YG YB C201 H114 H126 C901 S202 A603 S2L BrW SbY GyO C202 A602 H104 H727

146

D12.SL_A D13.DSUB2 D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

C31.BSL C32.DSUB3 C33.DD_S C34.AFR D 1.PRK D 2.AM_SW D 3.SL_2 D 4.SL_R D 5.SL_3 D 6.S_UP D 7.S_DOWN D 8.EG_SW D 9.M_SW D10.SL_1 D11.SL_F

C16.EP C17.F C18.ASUB1 C19.TEMP_SE C20.1/2 C21.1/8 C22.2S C23.EGM C24.IP_SW C25.FR C26.KO_P C27.ES_SE C28.3/4 C29.1/4 C30.DC

C 1.2S_SE C 2.POD_SW1 C 3.POD_SW2 C 4.DSUB4 C 5.TT C 6.AC C 7.ET C 8.BL C 9.BD C10.DSUB1 C11.HYDOL C12.DR C13.BSL_S C14.TF C15.WL

E12

166

LgL H117

LBr H205

A710 H203

273

LW A711

119

E11

LgR C703

118

GyB GyG GyL A809 A505 A501

810

E10

E26

GR YB WL GyG YO T103 S203 A806 T301 S205

224

103

B12

GL YBr SbP RG T104 S201 F701 H139

261

B11

LgB A604

130

O RL A609 E701 241 330 GB LG YGy LgL H121 E804 H122

B10

B20

A34

B3 B9

235

LgR A808

142

A33

B2 B8

RL A608

135

141

267

A32

A14

LgW LgY GR A502 A507 A701

A13

A708 H201

(BLACK)

A12

Note: See Section 62 for details.

ODOMETER SELECTION

A11

A26

Note: For factory use only.

A10

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E16.SPD E17.BATT E18.CANL1 E19.SS_P E20.CANLO E21.TM_M E22.B_SE2 E23.WT_SE E24.ALT E25.RXD1 E26.TGSP E27.INCH_SE E28.ASUB2 E29.CANHO E30.B_SE1

E 1.SSR_SO E 2.FC_SO E 3.KEY E 4.KEY E 5.GND E 6.GND E 7.GND E 8.GND E 9.+5V E10.TGEG E11.KEY E12.KEY E13.CANH1 E14.EGR2 E15.EGR1

B12.X_R B13.F_SO B14.B_SO B15.EG_SW2 B16.RIN1 B17.OUT_MD2 B18.N_R B19.BR_L B20.CAN_R1 B21.CAN_R2 B22.DOUT1 B23.OUT_FEW B24.MT B25.ET_SE B26.TXD1

A31.1/4_L A32.FR_L A33.3/4_L A34.EG_SW3 B 1.H_SO B 2. B 3.IP_SO B 4.R_SO B 5.MO_SO B 6.FR_SO B 7.SSL_SO B 8.ISW_R B 9.BZ B10.BSL_R B11.KO_R

A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.SS_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

A 1.2S_SO A 2.2_SO A 3.ES_R A 4.DD_SO A 5.3_SO A 6.HM A 7.LU_SO A 8.4_SO A 9.EG_SW1 A10.R_L A11.F_L A12.ST_L A13.WL_L A14.CW_L A15.ET_L

109

122

128

123

S9 S2

YB YG YBr S623 S733 S617 115

FUSE BOX (MAIN) R5

FUSE BOX (CAB)

003

O WR

G201 G301 G401 H103

BW BG

R1 R2

WRx2

BR B

ACC C

STARTER S/W

001

WBx2 G

LW B

001

002

WB F203

7 C304 F802 F803 G501 G802 S717

STARTER SWITCH

W 8

WR WR D501 D503 063

065

BW D504

004

G F703 014

810

WR RL

100

811

118

114

RS232C

BY GyG S707 S625 114

GR BY S622 S707

MCU PROGRAM REWRITE (NOT USED)

B202 B207

D505 D506

WR O

4 R H301

007

910

H111 W424

015

W BW W E104 E202 E202

R H401

G WR WR E107 E101 E106

911

060 061

A207 A307 A610 A706 E601 F102 F103 X502 X503 V703

R H302

062

912

1 B

754

E/G WATER TEMP. SENSOR (FOR INSPECTION)

R Y S812 S830 106 105

(NOT USED)

Note: These switches/connectors are for factory use only.

065

061

064

018

019

020

028

R H402 913

R H501 914

R H502

R H001 1 4

C303 V902 V002

RG RB 2 H018 H002 027

R WBr E302 021 022

915

029

H915 H017 C612

OL OR O 10 C310 C309 C301

060

L L L L L L S703 S704 S711 S712 F702 B504 005-A 005-B 005-C 005-D F902 005-b T902 T002

W 6

063

3 1

026

005-a

013

901

064

006

010

W W H601

G D502

062

14 RG OY T501

R G702

011

YL YO S725 S626

1 V GL S616 S709

B102 B107

F406 F502 F503 F602 F603

119

117

RL RG LR LW YR YW

116

1 1

DC-DC CONVERTOR

REVERSAL FAN S/W

F/R SWITCH/ STICK STEERING

3 6

YO LB S919 S924 YW S926

232

230

Lg LgL S825 S606 222 225 B LgY S834 223

233

RIDE CONTROL S/W

YGy V S709 S503 100

GyW S833

SbR S827 BY S707

Lg D103 013

RL S510 330

OUT

R D107

Y C104

242

240

260

EMERGENCY STEERING 3

BACK LAMP

114

021

531

This page illustrates the transmission is in neutral and key switch is in OFF position.

A 65ZV2/TMV2-09709-09700 US 2/4

K65V2U92010

65ZV-2 US 92-13 92 Drawing & Diagrams Electrical Wiring Diagram (3/4) (S/N 5051~5100)

Electrical Wiring Diagram (3/4) (S/N 5051~5100)

ECM

V24

V23

V22

V21

V20

V19

V18

V17

V16

V15

V14

V13

V12

V11

V10

106

E106

E107

E108

E109

V43

V42

V41

V40

V39

V38

V37

V36

V35

V34

V33

V32

V31

V30

V29

V28

V27

V26

V25

E98

E99

E100

E101 E102

E103

V62

V61

V60

V59

V58

V57

V56

V55

V54

V53

V52

V51

V50

V49

V48

V47

V46

V45

V44

E90

E91

E92

E93

E94

V81

V80

V79

V78

V77

V76

V75

V74

V73

V72

V71

V70

V69

V68

V67

V66

V65

V64

V63

E82

E83

E84

E85

E86

E110 E111 E112

E113

113

E104

E105

105

E95

E96

E97

E87

E88

E89

119

120

121

E119

E120

E121

E117

E118

E114

E115

E116

114

115

116

H115 W202

B W481 000

ATM. PRESS. SENSOR

YL T805

114 81

715

765

768

766

000

771

773

VW W203

765

GL GyL H105 W201

GW H710 764

767

Gy H703

766

772

BrG T401

768

738

S4W GR GyR H714 H701 H713

S4R H705

GyB H720

S4W GB YL YR YW VR H714 H721 H708 H707 H706 H711

GyB H720

769 775

770 779

778

777

774

799 799

YL T805

715

YB T801

WR D101

YB T801

015

YL S2L T407 C202

716

YO G001

747

748

S2H Gy C201 A506

BR BrG F101 H134

749

716

726

722

WY BrW BrR W102 A606 A605 758

732

730

106 H734

S6B

GyR H709 105

S6W S6S BLg YL YW H733 H735 H731 H718 H716

GyR H709 113

776

790

791

789

798 798

116

797

YR H717

S5B S5W S4S/S5S S4B H724 H723 H725 H715

115

RG H729

LgW H740

VW BP GL W461 W460 W471 3

B VR BG E402 H704 H702

LgR H738

793

795

LgBr H737

LgY H739

RG H719

119

120

121

792

796

794

B This page illustrates the transmission is in neutral and key switch is in OFF position.

W1 W S715 1

161

V S709

RESISTOR FOR E/G SPEED

100

WY W408 758

2 65ZV2/TMV2-09709-09700 US 3/4

K65V2U92011

65ZV-2 US 92-14 92 Drawing & Diagrams Electrical Wiring Diagram (4/4) (S/N 5051~5100)

Electrical Wiring Diagram (4/4) (S/N 5051~5100)

* ) &* *$%'

# !%)$ ) & *$%'

& * ' + * ) * )

! ! !

)

) * % *$

(

# % % % %

(

) % +

)* + %) %

% )

) % % )

# * % *

! ! ! ! ! !

)

$* $% *

*+% % )

! ) % (

%) + * ) * ) & , !'

)+ ) )

%) * )

! !

)#% % )

! ! ! ! ! ! !

)

! !

) % # * % *

* % , %

! !

! $, * % , %

! !

! $, * % %

# * % *

) % )

)

#) %%$ + , ) %

# %

(

* ) % )* % , %

" !

(

" " ! !

(

" !

! !

" !

(

! !

# %

! !

(

! !

% %+ , #) + $% %

! !

% *$ ) %

$ %%$ %

) % * % , & )* '

*$% + % *$

& %'

! !

) !% & '

! !

) % %

+ % % % %

+ % + +! &%+'

# * * %

&# '

! !

%##*+*% )$* % &% ' % *$ ) %

! !

(

# !%)$ ) & *$%'

* ) &* *$%'

%##*+*% )$* % &% ' * % , %

! ! !

& * '

! &!'

" " " "

! & '

)

& * ' + * ) * )

%) + * ) * ) & , !'

! ) % (

This page illustrates the transmission is in neutral and key switch is in OFF position.

65ZV-2 US 92-15 92 Drawing & Diagrams Electrical Wiring Diagram (1/4) (S/N 5101~5400)

Electrical Wiring Diagram (1/4) (S/N 5101~5400)

&+'

* (

$ " " #

& # & #

% (

' '

! & ' & '

! , &" # '

(

% $

(

% (

& " '

& '

( % $

$ $

$ %

& " '

% *

! ! #

& '

( )

(

( )

(

& 0 # 1 ' & 0 # 1 ' - & 0 # 1' & 0 # 1'

( $ ) *%

( $ % ( *%

% %

(

& '

(

% (

% %

)

% ( " $

( "

& " '

# %

(

( (

# %

$ $

" & '

# ! #

" # %

(

( $

& " '

(

& '

! " # #!

( ( ( ( ( ) % % %(

( % % ) %

( ( ( ( ( ) ( ( ( ( " ( ( ) ( ( ( ( " (

( ( ( ( ( % %

" ( ( ( ( (

( ( ( ( ) % % %(

" " " " * ( ( " " " %

" " " " " $ " (% % (

" " " " ( % %

& '

( (

(

$ $

& " '

* -

(!$ %

$ $

(

! #

& " '

& '

(

( %

/ %

% ( " $

( (

& '

(

! $ ( & '

$ $

% "

! ,

% " ( "

(

$ (# ! #

" ## "

( %

"! ! % & '

$! % & '

& 0 # 1 0 # 1'

" %

( !" %

( (

(

( (

(

( (

" !# %

! !" %

( ( ( ( (

( (

% %

$ " " #

& # 1 & # 1

(

% %

$ " "

)

(

)

% " "

( $ $

(

( % % % "

( (

) $

% - -

(

$ " " " (

! !" ( !"

(

" & ! " #'

& '

( " ! #

) $

$! $ #!

(

% )

(

# (

" !# ! # (

!# (

(

" ! ! # " ! # & '

( % ( ( (

)

% ( *(

(

)(

(

( ( )

( (

(

) ) % ( (

(

( (

( !#

% *

!# # #

# ( !#

!"! # $!# % & ' & '

!"! # $ " ! #

" "

$ $ " " " " " % ( (

$ $ ( %

This page illustrates the transmission is in neutral and key switch is in OFF position.

65ZV-2 US 92-16 92 Drawing & Diagrams Electrical Wiring Diagram (2/4) (S/N 5101~5400)

Electrical Wiring Diagram (2/4) (S/N 5101~5400) * + *! + *! + * +

* &" * * ( * +& * ( ! * + * + * + * * )" * & *'( + * * ( ! * +

* + ! * + ! * * * (" * (" * (" * (" *, * * * * ( * *

*)+ * + ! * + ! * + * '( *! + " *(+ * + * (+ * (+ *"! *! + * * + * )"

* + * + * + * + * + ! * *'&+ ! * + ! * !+ ! * + ! * + ! *' + * * + * !+

* + *"+ ! * + ! * &+ * + * + * + * + * + * + * + * + * &+ *(+ * +

* + ! * + ! * + *""+ ! * + ! * * + ! * + ! * + * + * + * + * + * + * +

" * + " *" " * " " *'( + " *!"+ " * " * + " * + " * & " *'( " * !+ " * " * " * + " * +

* *" *""+ * " *& " * + " * + " * + " * + " * + & " * +"! ( " * + " * + " * + " * +

* & * * * &+ * * * * *'&+ * * !+& * + * * *"

* + *&!"+ *&!"+ *" * * * * * " *" * "! *" * + * *

/ ( 1 03 / ( 1 0 / ( 103 / ( 10

Note:

9 ;.679 $ ?>5 9:=$*

'!(

# )

$ $ $

) / ( 10 2 / ( 10

" "

$ #

" "

" " "

" "

- -

" " "

" "

) )

& ! ' /(! "0

! ! !

" %

&* ( ! / ! '( & '!(0

( ! '!(

Note: @5>5 >A876@5> 69::5679 > . 5 ;9 ;.679 $ ?>5 9:=$*

! ) / 4 13 4 10

! & !

!) / 0

" " " " "

& & % !

!) / '(0

/ ( 1 03 / ( 1 0 10 / ( 103 / (

% $

# "

/ ( 1 0 2 / ( 1 0

% $!

$ !

$ # ! %

/ 0

# #

55 56789: ;9 <57.8=>*

!"! '!(

Note:

" " !( !

'" !( ! '

' ' '( !

# "

( '(

This page illustrates the transmission is in neutral and key switch is in OFF position.

65ZV-2 US 92-17 92 Drawing & Diagrams Electrical Wiring Diagram (3/4) (S/N 5101~5400)

Electrical Wiring Diagram (3/4) (S/N 5101~5400)

ECM

V24

V23

V22

V21

V20

V19

V18

V17

V16

V15

V14

V13

V12

V11

V10

106

E106

E107

E108

E109

V43

V42

V41

V40

V39

V38

V37

V36

V35

V34

V33

V32

V31

V30

V29

V28

V27

V26

V25

E98

E99

E100

E101 E102

E103

V62

V61

V60

V59

V58

V57

V56

V55

V54

V53

V52

V51

V50

V49

V48

V47

V46

V45

V44

E90

E91

E92

E93

E94

V81

V80

V79

V78

V77

V76

V75

V74

V73

V72

V71

V70

V69

V68

V67

V66

V65

V64

V63

E82

E83

E84

E85

E86

E110 E111 E112

E113

113

E104

E105

105

E95

E96

E97

E87

E88

E89

119

120

121

E119

E120

E121

E117

E118

E114

E115

E116

114

115

116

H115 W202 B

ATM. PRESS. SENSOR

YL T805

114 81

715

765

768

766

000

771

773

VW W203

765

GL GyL H105 W201

GW H710 764

767

Gy H703

766

772

BrG T401

768

738

S4W GR GyR H714 H701 H713

S4R H705

GyB H720

S4W GB YL YR YW VR H714 H721 H708 H707 H706 H711

GyB H720

769 775

770 779

778

777

774

799 799

YL T805

715

YB T801

WR D101

YB T801

015

YL S2L T407 C202

716

YO G001

747

748

S2H Gy C201 A506

BR BrG F101 H134

749

716

726

722

WY BrW BrR W102 A606 A605 758

732

730

106 H734

S6B

GyR H709 105

S6W S6S BLg YL YW H733 H735 H731 H718 H716

GyR H709 113

776

790

791

789

798 798

116

797

YR H717

S5B S5W S4S/S5S S4B H724 H723 H725 H715

115

RG H729

LgW H740

VW BP GL W461 W460 W471 3

B VR BG E402 H704 H702

LgR H738

793

795

LgBr H737

LgY H739

RG H719

119

120

121

792

796

794

B This page illustrates the transmission is in neutral and key switch is in OFF position.

W1 W S715 1

161

V S709

RESISTOR FOR E/G SPEED

100

WY W408 758

2 65ZV2/TMV2-09709-09921 US 3/4

K65V2U92019

65ZV-2 US 92-18 92 Drawing & Diagrams Electrical Wiring Diagram (4/4) (S/N 5101~5400)

Electrical Wiring Diagram (4/4) (S/N 5101~5400)

* ) &* *$%'

# !%)$ ) & *$%'

* ) &* *$%'

& * ' + * ) * )

)

) * % *$

(

% % ) #) , ) %

(

) %

)* + %) %

! $, * % , %

* % , %

)#% % )

) % % )

# * % *

! ! ! ! ! !

)

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%) + * ) * ) & , !'

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)+ ) )

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(

%) * )

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) % # * % *

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! $, * % %

)

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# %

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(

* ) % )* % , %

(

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! !

# %

# % % % %

(

% %+ , #) + $% %

+ % + +! &%+'

*$% + % *$

$ %%$ %

) % * % , & )* '

& %'

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) % %

) !% & '

+ % % % %

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# * * %

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&# '

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J602 J603

(

! ! !

# !%)$ ) & *$%'

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! !

! ! !

& * '

! &!'

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! & '

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! ) % (

This page illustrates the transmission is in neutral and key switch is in OFF position.

65ZV-2 US 92-19 92 Drawing & Diagrams Electrical Wiring Diagram (1/4) (S/N 5401~)

Electrical Wiring Diagram (1/4) (S/N 5401~)

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/ #$

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)

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) )

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% %

% + +

% %

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) "

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# %

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) (

)

+ ) (

)

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% %

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& '

# %

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) % % ( %

) ) ) ) ) ( ) ) ) ) " ) ) ( ) ) ) ) " )

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& '

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& " '

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% %

)

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$ $

% )

! # ! ! #

& " '

& '

)

) %

) % $

)

% *

& '

% "

! ,

$ $

! $ ) & ' %

) %

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! , &" # '

% " "

% )

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! & ' & '

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$! % & '

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) !" %

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)

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) $ $

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( $

$! $ #!

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)

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!"! # $ " ! #

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$ $ " " " " " % ) )

$ $ ) %

This page illustrates the transmission is in neutral and key switch is in OFF position.

65ZV-2 US 92-20 92 Drawing & Diagrams Electrical Wiring Diagram (2/4) (S/N 5401~)

Electrical Wiring Diagram (2/4) (S/N 5401~)

Note:

5 7.235 $ ;:1 569$*

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& & % !

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* *" *""+ * " *& " * + " * + " * + " * + " * + & " * +"! ( " * + " * + " * + " * +

* & * * * &+ * * * * *'&+ * * !+& * + * * *"

* + *&!"+ *&!"+ *" * * * * * " *" * "! *" * + * *

$ !

$ $ $

$ # ! %

/ 0

# #

11 123456 75 813.49:*

!"! '!(

Note:

* + *! + *! + * +

* &" * * ( * +& * ( ! * + * + * + * * )" * & *'( + * * ( ! * +

* + ! * + ! * * * (" * (" * (" * (" *, * * * * ( * *

*)+ * + ! * + ! * + * '( *! + " *(+ * + * (+ * (+ *"! *! + * * + * )"

* + * + * + * + * + ! * *'&+ ! * + ! * !+ ! * + ! * + ! *' + * * + * !+

* + *"+ ! * + ! * &+ * + * + * + * + * + * + * + * + * &+ *(+ * +

* + ! * + ! * + *""+ ! * + ! * * + ! * + ! * + * + * + * + * + * + * +

" " !( !

'" !( ! '

' ' '( !

# "

( '( $

This page illustrates the transmission is in neutral and key switch is in OFF position.

65ZV-2 US 92-21 92 Drawing & Diagrams Electrical Wiring Diagram (3/4) (S/N 5401~)

Electrical Wiring Diagram (3/4) (S/N 5401~)

" & &

"' &

% "

& "'

(" &

"' &

" %$ % & & & &

% & &

"' &

& & & &

% &

"' &

% ( (

$) & & & &

%$ % & &

"' &

" "' & & &

"$ "'$ &

" &

$) &

$) ( &

$)% &

" &

This page illustrates the transmission is in neutral and key switch is in OFF position. ! " #

65ZV-2 US 92-22 92 Drawing & Diagrams Electrical Wiring Diagram (4/4) (S/N 5401~)

Electrical Wiring Diagram (4/4) (S/N 5401~)

* ) &* *$%'

# !%)$ ) & *$%'

* ) &* *$%'

& * ' + * ) * )

(

# % % % %

)* + %) %

% % ) #) , ) %

) %

% )

! $, * % %

! $, * % , %

* % , %

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# * % *

! ! ! ! ! !

)

$* $% *

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(

%) * )

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)

) % # * % *

#) %%$ + , ) %

# * % *

) % )

! !

)

# %

(

* ) % )* % , %

! !

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(

! !

" !

# %

" " ! !

" !

(

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! !

(

% %+ , #) + $% %

! !

$ %%$ %

*$% + % *$

+ % + +! &%+'

& %'

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% *$ ) %

) * % *$

) % %

! !

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+ % % % %

! !

%##*+*% )$* % &% ' % *$ ) %

# * * %

)

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! !

J602 J603

(

! ! !

# !%)$ ) & *$%'

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! !

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& * '

! &!'

" " " "

! & '

)

& * ' + * ) * )

! ) % (

This page illustrates the transmission is in neutral and key switch is in OFF position.

65ZV-2 US 92-23 92 Drawing & Diagrams Electrical Wiring Diagram

Electrical Wiring Diagram Way of looking at connectors Machine control unit (MCU)

White (Male connector)

MCU MCU A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.SS_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

A 1.2S_SO A 2.2_SO A 3.ES_R A 4.DD_SO A 5.3_SO A 6.HM A 7.LU_SO A 8.4_SO A 9.OTH_OUT A10.R_L A11.F_L A12.ST_L A13.WL_L A14.CW_L A15.ET_L

Female connector

MCU

A31.1/4_L A32.FR_L A33.3/4_L A34.EG_SW1 B 1.H_SO B 2.PWM_SO B 3.IP_SO B 4.R_SO B 5.MO_SO B 6.FR_SO B 7.SSL_SO B 8.BSL_SO B 9.BZ B10.BSL_R B11.KO_R

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

A27

A28

A29

A30

A31

A32

A33

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B21

B22

B23

B24

B25

E 1.SSR_SO E 2.FC_SO E 3.KEY E 4.KEY E 5.GND E 6.GND E 7.GND E 8.GND E 9.+5V E10.TGEG E11.KEY E12.KEY E13.CANH1 E14.EGR2 E15.EGR1

B20

SbO LgW LgY GR OSb YBr RL YB A612 A502 A507 A701 V204 A618 A608 A616 193 192 173 135 211 413 235 411 YG LgB GW LY Gy GY LgR YL A708 A506 A807 A808 A617 A619 A604 H707 H201 749 169 130 412 414 224 V212 0 YR Sb GyB GyG GyL LP RL H714 A615 A609 A504 A809 A505 A501 H208 T801 410 241 194 103 753 190 149 GB LG YGy LgL LO YSb LLg LW SbP H736 H202 E804 K204 A710 A901 H721 A711 F202 267 V303 242 261 H203 403 140 V302 202 1

A34

B12.X_R B13.F_SO B14.B_SO B15.EG_SW2 B16.RIN1 B17.OUT_MD2 B18.N_R B19.BR_L B20.CAN_R1 B21.CAN_R2 B22.DOUT1 B23.OUT_FEW B24.MT B25.ET_SE B26.TXD1

B26

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E27

E28

E29

E30

E31

E32

E33

E34

C701 E007 C902 K203 E801 T102 114 H724

100 C702 E803 E004 K202 T101 H708

C16.EP C17.F C18.ASUB1 C19.ASUB2 C20.1/2 C21.1/8 C22.2S C23.EG_H C24.IP_SW C25.FR C26.KO_P C27.ES_SE C28.3/4 C29.1/4 C30.DC

C31.BSL C32.EG_M C33.DD_S C34.AFR D 1.PRK D 2.AM_SW D 3.SL_2 D 4.SL_R D 5.SL_3 D 6.S_UP D 7.S_DOWN D 8.EG_SW D 9.M_SW D10.SL_1 D11.SL_F

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C27

C28

C29

C30

C31

C32

C33

C10

C26

YG YB S2H SbY GyL G C201 H725 H755 C901 T302 A603 171 180 415 116 401 G S2L BrW SbY GyO WL YL E003 C202 A602 H711 H740 H766 T304 234 402 172 220 707 117 L L W Y G D203 D204 H743 H720 D107 005-C 005-D 161 160 010 B BR LgB L L B BY Y V E002 H751 D201 D202 H734 236 221 005-A 005-B 159 1

C 1.2S_SE C 2.DSUB2 C 3.DSUB4 C 4.BSLC 5.TT C 6.AC C 7.ET C 8.BL C 9.BD C10.DSUB1 C11.DSUB3 C12.DR C13.BSL+ C14.TF C15.WL

E12

Male connector S5

E11

LgR C703 166

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E10

E26

GR YB WL GyG YO T103 T303 A806 H769 T305 811 115 400 754 118 WR SbW GL YBr SbP RG H739 X601 T104 T301 F701 H770 170 203 810 119 145 331 SbR LgBr L BrB LgW LR F102 X501 T001 T901 F901 H204 208 104 273 258 101 146 LB GB LBr LgR LgL BL H205 V101 H206 H209 E502 E001 147 278 148 150 225 237

E16.SPD E17.BATT E18.CANL1 E19.SS_P E20.CANLO E21.TM_M E22.B_SE2 E23.WT_SE E24.ALT E25.RXD1 E26.TGSP E27.INCH_SE E28.SC_P E29.CANHO E30.B_SE1

BrR SbR YB YBr B Y GyW LgY K205 E802 H716 H744 T202 E603 E501 251 240 406 408 105 260 223 YL YG GL GyW GB Lg H730 H701 A302 A202 V102 E503 407 409 265 200 277 222 BrY R BW SbO Sb YR Gy H726 T203 F005 H762 H748 F303 H702 181 106 271 183 184 750 405 GyB P PL LgL H754 H750 S102 S103 266 107 108 182

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D21

D22

D23

D24

D25

D26

PW YW PB LLg BrG GW LB H210 B002 F004 V201 E006 S201 E012 152 165 255 210 230 111 233 YL LP PB YSb YV YO G101 F001 S301 G901 A407 E005 124 168 110 125 231 232 LY LW B LR B703 B709 B706 121 126 120 GO PG LG LBr LO B503 S401 B702 B708 B701 164 109 122 128 123 9

D2 D8

D20

C34

D12.SL_A D13.SS_N D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

Black (Female connector)

Female connector 115V2E92016

65ZV-2 US 92-24 92 Drawing & Diagrams Electrical Wiring Diagram

40 poles connector

6 poles connector

Female connector Male connector

Male connector

Female connector

Black (Female connector) Female connector

H7 10

6 C201 C202 C203 F704 T406 T405 T404 T403 RL S2H S2L S2S YL D101 A606 S534 T402 WR BrW SbLg RLg YO H808 A607 S811 S723 S716 WY BrB BrY GyO Y

S708 A503 A605 A802 Y WG BrR BG GyR 40 36

C002 F203 S615 S722 S730 Sb SbW SbY SbY BLg C404 C001 G004 C309 F103 BL YV BrG OR SbY C402 C003 C005 G002 C307 F302 BrW GyW PW PB GyR C403 D105 C006 G003 C308 S715 BW GyY PG PL W 35 31

PARKING S/W

C401 C004 G001

Male connector

36 BrR P743

Male connector

W PL GyY PG P701 P724 M803 P741

Y WY BrB BrY GyO P201 P744 M401 L701 M902

BrW GyW PW PB GyR P722 P711 P725 M802 P749

BL YO P734 P720

OR SbY YV BrG BL P709 P702 P734 M801 P713 BLg Sb P723 P731

YL S2H S2L S2S P901 P902 P903 P710 6

Female connector

SbY SbY M303 M203 1

Y B

L D206

LgG H137

GyR Y P742 M901

WR P739

White (Male connector)

GO SbW S901 A712

B 1

White (Male connector)

Black (Female connector)

90V2U92009

65ZV-2 US 92-25 92 Drawing & Diagrams Electrical wiring diagram abbreviation chart

Electrical wiring diagram abbreviation chart (S/N 5001~5400) INSTRUMENT PANEL —

INSTRUMENT PANEL

MCU

Parking brake lamp

A20

AUTO lamp

A21

Charge lamp

Air cleaner clogging alarm

—

— Auto shift indicator lamp

A22

—

B26

Communication TXD1

E1 E2

— Fan speed control solenoid valve

MCU C4 C5 C6

MCU

—

D10

Shift lever 1

D11

Shift lever F Shift lever A

Air cleaner clogging switch

—

T/M oil temperature alarm

Meter (Speed/Tacho) +

A23

Engine water temperature alarm

Meter (Speed/Tacho) –

A24

Engine oil pressure alarm

Brake oil pressure alarm

Declutch lamp

A26

MCU error (failure alarm)

Preheating lamp

A27

Air cleaner warning lamp

+24 V power supply

Work lamp

A28

Brake pressure warning lamp

Power supply GND

C12

—

D17

Shift hold switch

Secondary steering

Central alarm lamp

A29

Neutral indicator lamp

+5 V output

C13

Lower kickout set-up

D18

S/S shift selection switch

GND

GND (–)

S/S shift switch F

Reversal fan indication lamp

EG2

Engine warning lamp

EG1

Engine protection lamp

EG3

Engine stop lamp

—

MCU

Power supply +24 V

—

D12

Power supply +24 V

—

D13

—

Power supply GND

—

D14

Downshift button

—

Power supply GND

C10

—

D15

Declutch set up

Power supply GND

C11

D16

Odometer selection

S/S indicator lamp

A25

Hydraulic oil level switch

—

A30

—

E10

—

C14

—

D19

—

A31

—

E11

Power supply +24 V

C15

—

D20

—

A32

E12

Power supply +24 V

C16

—

D21

Declutch switch

E13

—

C17

—

D22

Kick out set up

Reversal fan indicator lamp

High-beam lamp

A33

FR switch, S/S switch indication lamp

Turn signal (left) lamp

A34

—

E14

—

C18

D23

—

WTM

Engine water temperature gauge (sensor)

Turn signal (right) lamp

—

E15

E/G speed sensor 1

C19

—

D24

—

TTM

T/M oil temperature gauge (sensor) —

(+)

—

E16

Machine speed sensor

C20

—

D25

Hour meter (–)

—

E17

Power supply

C21

—

D26

Hour meter (+)

Instrument panel illumination

MCU

R solenoid valve

B5 B6

E18 —

Reversal fan solenoid valve

—

E19

—

C22

Efficient loading system switch

C23

E/G mode selection switch

E20

Communication CAN L0

C24

—

Efficient loading system solenoid valve

—

E21

T/M oil temperature gauge

C25

Reversal fan (manual) switch

Fuel gauge (sensor)

2nd speed solenoid valve

—

E22

Brake oil pressure sensor 2

C26

Boom angle sensor

C27

Secondary steering oil pressure sensor

C28

—

C29

—

Secondary steering motor relay

Buzzer

E23

Hydraulic oil temperature sensor

—

Ride control solenoid valve

B10

Lower kickout relay

E24

Alternator

—

3rd/4th speed solenoid valve

B11

Lift kickout relay

E25

Communication RXD1

—

Hour meter

B12

MCU fault relay

E26

F solenoid valve

— GND

Throttle opening sensor

GND

— FM

—

B13

GND (–)

4th speed pilot lamp

B14

—

+ 24 V power supply

—

B15

—

E28

—

A10

B16

Communication RINI

E29

—

A11

B17

—

E30

Back-up lamp —

—

A12

—

A13

Steering oil pressure warning lamp —

E27

—

C30

—

C31

—

C32

—

Communication CAN H0

C33

Ride control switch

Brake oil pressure sensor 1

C34

Auto fan reversal switch

Declutch sensor (brake oil pressure sensor) —

B18

Neutral relay

E31

T/M oil temperature sensor

Parking switch

B19

Brake lamp

E32

Air temperature probe

Auto/Manual selection switch

Neutral

A14

Central warning lamp

B20

—

E33

Shift lever 2

GND (–)

A15

E/G coolant temperature warning lamp

B21

—

E34

E/G coolant temperature gauge

Shift lever R

1st speed indication

A16

T/M oil temperature warning lamp

B22

A17

Efficient loading system oil pressure sensor

Shift lever 3

2nd speed indication

—

3rd speed indication

A18

4th speed indication

A19

— 1st speed solenoid valve —

B23

Communication DOUT1 —

—

B24

Meter output (Speed/Tacho)

—

B25

E/G coolant temperature sensor

—

— S/S shift switch R

65ZV-2 US 92-26 92 Drawing & Diagrams Electrical wiring diagram abbreviation chart (S/N 5401~) INSTRUMENT PANEL (A5) +

INSTRUMENT PANEL (A6) F/R switch

MCU A18

BATT

Ride control

A19

—

B25

E/G coolant temperature sensor

—

GND

GND(-)

Reversal fan

A20

—

B26

Communication TXD1

—

D10

Shift lever 1

D11

Shift lever F Shift lever A

EG4

2nd speed indication

EG1

Engine protection lamp

A22

—

Fan speed control solenoid valve

3rd speed indication

EG2

Engine warning lamp

A23

—

Power supply +24 V

—

D12

4th speed indication

EG3

Engine stop lamp

A24 A26

SUB2

—

Brake alarm Engine oil pressure alarm

—

Secondary steering

WTM

Engine water temperature gauge

—

Power supply +24 V

—

D13

Power supply GND

—

D14

—

Power supply GND

C10

Power supply GND

C11

A27

Air cleaner warning lamp

A28

Brake pressure warning lamp

Power supply GND

C12

A29

Neutral indicator lamp

+5 V output

C13

—

— Downshift button

D15

Declutch set up

D16

Odometer selection

—

D17

Shift hold switch

Lower kickout set-up

D18

S/S shift selection switch S/S shift switch F

Hydraulic oil level switch

Engine water temperature alarm

A30

—

E10

—

C14

—

D19

T/C (T/M) oil temperature alarm

A31

—

E11

Power supply +24 V

C15

—

D20

—

Air cleaner clogging alarm

A32

E12

Power supply +24 V

C16

—

D21

Declutch switch

—

Charge lamp

A33

—

E13

—

C17

—

D22

Kick out set up

—

A34

—

E14

—

C18

—

SUB1

—

E15

E/G speed sensor 1

C19

—

TTM

T/C (T/M) oil temperature gauge

—

E16

Machine speed sensor

C20

—

Fuel gauge

—

E17

Power supply

EWL

—

Parking brake lamp

SM TA

Speed meter Tachometer

INSTRUMENT PANEL (A6)

MCU

B5 B6

E18 —

Reversal fan solenoid valve

E19 E20

C21 — —

Communication CAN L0

—

D24

—

D25

—

D26

C22

Efficient loading system switch

C23

E/G mode selection switch

C24

—

E21

T/M oil temperature gauge

C25

Reversal fan (manual) switch

2nd speed solenoid valve

—

E22

Brake oil pressure sensor 2

C26

Boom angle sensor

C27

Secondary steering oil pressure sensor

C28

—

C29

—

C30

—

Secondary steering motor relay

Buzzer

E23

Hydraulic oil temperature sensor

Ride control solenoid valve

B10

Lower kickout relay

E24

Alternator

3rd/4th speed solenoid valve

B11

Lift kickout relay

E25

Communication RXD1

Hour meter

B12

MCU fault relay

E26

—

B13

F solenoid valve

4th speed pilot lamp

B14

—

B15

—

B16

Communication RINI

E29

—

B17

—

E30

Turn signal (Right) lamp

Work lamp

High-beam lamp

(+)

Instrument panel illumination

A10

AUTO lamp

A11

Back-up lamp

E28

Declutch sensor (brake oil pressure sensor)

C31

—

C32

—

Communication CAN H0

C33

Ride control switch

Brake oil pressure sensor 1

C34

Auto fan reversal switch

—

Turn signal (Left) lamp

A12

Neutral indication

A13

Central alarm lamp

A14

Central warning lamp

B20

—

E33

—

A15

E/G coolant temperature warning lamp

B21

—

E34

E/G coolant temperature gauge

T/M oil temperature warning lamp

B22

Efficient loading system oil pressure sensor

Declutch lamp

A16

Preheat lamp

A17

Steering oil pressure warning lamp

E27

—

B18

Neutral relay

E31

T/M oil temperature sensor

Parking switch

B19

Brake lamp

E32

Air temperature probe

Auto/Manual selection switch

—

Shift lever 2

Shift lever R

Shift lever 3

B23

Communication DOUT1 —

—

D23

Efficient loading system solenoid valve

—

R solenoid valve

Throttle opening sensor

Controller failure alarm —

Reversal fan indicator lamp

—

CANL

Air cleaner clogging switch

—

Hour meter

CANH

S/S indicator lamp

1st speed indication

A25

—

Auto shift indicator lamp

Meter output (Speed/Tacho)

MCU

A21

B24

MCU

+24V power supply

—

1st speed solenoid valve

MCU

—

S/S shift switch R

65ZV-2 US 92-27 92 Drawing & Diagrams Electrical Wiring Diagram (CAB)

Electrical Wiring Diagram (CAB)

, * - * *

% !

+ + +

! !

* + ,- - * + ,- * + ,-

% !

$ &

−

( & &

' '

−

# & # −

# !

* + ,-

* + , - * + , *

% !

* + ,- - * + ,- * + ,-

' '

* - + , - * - + , *

* + ,

* + ,- - * + ,-

* + , - * + ,

' '

* + , - * + , *

.$ . ( ! (

! (!

& #& #& & # #

( /01)

# & ( # −

* + ,- - * + ,- * + ,-

* - + , - * - + , *

−

$ % &

* + , - * + , *

$ #

% !

* + ,- - * + ,- * + ,-

$ % &

(

* - + , - * - + , *

) ( ( % % ! # $ $ ! # ! ! ! ! $ ! (!

* + ,- ' - * + ,- * + ,-

* + , - * + , * + ,

65ZV-2 US 92-28 92 Drawing & Diagrams Electrical Wiring Diagram (CAB)

Cab S/N (CB18 ~0881):65~90ZV2 (CB14 ~0292):92,95ZV2 Working lamp (front) (CB19 ~0164):115ZV2

(A4) (A6)

(A2)

Room lamp

Working lamp (rear)

(B3) Wiper motor (rear) (A3) Car radio

(B4)

Speaker

(B2)

Cigar socket (B1)

Wiper S/W (rear)(A5) Wiper S/W (front)(A8)

(A7)

(A1)

Relay wiper intermittent

Wiper motor (front)

Cigar socket (+24V)(OPT) (B6)

(B5)

MODM

(B9) (C1~C3)

Option

CAN (Resistor) (B8)

To floor board

K70T2U92007

65ZV-2 US 92-29 92 Drawing & Diagrams Electrical Wiring Diagram (CAB)

Cab S/N (CB18 0882~ / CB34):65~90ZV2 (CB14 0293~ / CB33):92,95ZV2 (CB19 0165~ / CB37):115ZV2

. *

.)2 3# * * $ '(1 ) 4 5 )3# * * '(1 4 )3# * *

' ! !

! !

* .)2 3# * * 5 * $ '(1 4 ). 5 )3# * * $5 * '(1 4 )3# * *

! " #

! '( ! ) ! '( +! , - ! ! !

! " $# %&

.)2 3# * * 5 * $ '(1 4 ). 5 )3# * * $5 * '(1 4 )3# * *

/%0/ *) *

1 +!

.)2 3# * * $ '(1 ) 4 5 )3# * * '(1 4 )3# * *

65ZV-2 US 92-30 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 5001~5050)

Electrical Connection Diagram (1/2) (S/N 5001~5050)

STARTER S/W B

BR ACC R1 R2

ACC' C

(L) (005-b) (005) F5 L2

PREHEAT OFF ON START

TO PARKING S/W

(L) (005-a)

30A G (010)

F10

Lx4 (005-A~005-D)

ACC' (086) [W3]

(900) [W5]

12V

E05 E06 E17

100

30A

WL (707)

BATTERY ECM (V24)

(060) (901) W [W5]

15A

BATTERY RELAY

F13

23A

STARTER

(013) (Lg)

LG (122)

LY (121)

[R5]x6 (910~ 915)

(701) [R5] (703) RL1.25

(702) [BW5]

B S

(ZV: S/N 5015~) (706) (TMV: S/N 4011~) WL1.25

F/R SELECTION S/W (OPT)

(723) [BR5]

L B

70A

R R1.25 (710) ALTERNATOR (711) BrL

F13 (725) [BR5]

(724) [BR5]

SHIFT INPUT SELECTION S/W (OPT)

YV (231)

ARM WREST S/W (OPT)

GLOW PLUG

ECM(V10)

TO PILOT LAMP ACC'

F13 DECLUTCH

(013) (Lg)

(YL) (124)

DOWNSHIFT S/W

YSb (125) LP (168)

LIFT KICKOUT SET-UP

BrG (255)

LOWER KICKOUT SET-UP

BW (271)

Lg (222) LgY (223) (Y) (105) (R) (106) P (107) PL (108) PG (109) PB (110)

15 15A

30 20A

14 10A

29 20A

28 10A

12 15A

11 10A

10 15A

25 20A

15A

24 10A

15A

23 10A

10A

15A

21 15A

30A

20 10A

15A

19 10A

10A

LgG

LLg (165)

DECLUTCH

OFF

E/G OIL PRESS. S/W F5

PARKING S/W

B04

D03 D10

LIFT KICKOUT RELAY LOWER KICKOUT RELAY

YGy (242)

A18

D19 A02

D18

A08

V (100)

~5008, HYD. OIL (S/N ~4002) LEVEL S/W (S/N 5009~, 4003~) AIR CLEANER CLOGGING S/W

SECONDARY STEERING MOTOR RELAY COIL (OPT)

LR (146)

F SOLENOID VALVE

E21

BOOM ANGLE SENSOR

BrR (251)

LBr (148)

R SOLENOID VALVE

DECLUTCH SENSOR

LgR (166)

(141) LY

1ST SPEED SOLENOID VALVE

BRAKE OIL PRESS. SENSOR 1

(142) LG

2ND SPEED SOLENOID VALVE

E10

SECONDARY STEERING OIL PRESS. SENSOR (OPT)

E26 SbR (240)

GyG (754)

E/G COOLANT TEMP. SENSOR 4TH SPEED PILOT LAMP

GyL (180)

T/M OIL TEMP. SENSOR

(G) (415)

A17

LgL (182)

GyO (220)

HYD. OIL TEMP. SENSOR

D23 D22

A04 A01

C13 B06

C25 E02

LgL (261) GB (267) LgL (225)

REVERSAL FAN SOL. VALVE (OPT) (226) LgB

(221) LgB

C34 C30

RIDE CONTROL SOLENOID VALVE (OPT) EFFICIENT LOADING SYSTEM SELECTION SOL. VALVE (OPT)

FAN SPEED CONTROL SOL. VALVE

(E09)

E/G SPEED SENSOR ECM(V8)

MACHINE SPEED SENSOR

A10

E23 B23(OUT_FEW) E33(OUT_RES) E25(RXD0) B26(TXD0) B17(OUT_MD2)

METER OUTPUT (TACHOMETER)

(420) (+) OL

(−)

(421) (+) OB

(−)

TACHOGRAPH E/G SPEED (OPT) TACHOGRAPH GROUND SPEED (OPT)

YSb (403)

HOUR METER DRIVE

(LB) (138) (RG)(331)

TO BACK-UP LAMP TO BRAKE LAMP (100) V

(115) (YB) (116) (YG) (117) (YL) (118) (YO) (119) (YBr)

C18

+5V FEW RESET RXD TXD MD2 GND

MCU PROGRAM REWRITE (For factory use only)

E (RIN1)B16 (DOUT1)B22

Y (160)

T/M OIL TEMP. GAUGE

(400) (WL )

(E09)

V (100)

W (161)

E/G COOLANT TEMP. GAUGE

(BrW) (402)

S3R

Y (159)

E15 E16

(CANH0)E29 (CANL0)E20

E08

GL (810)

RS232C

GR (811)

S2H S2L

S2H

E01

S2L

MAIN MCU

C12 C02

S3W

BUZZER

(YB ) (401)

E32

S3B

THROTTLE OPENING SENSOR

S/S INDICATOR LAMP (OPT) BZ

E B19

E07

A07

A06

E31

D17 D15

LgBr (104)

B25

BY (114) B14

(LgB) (224)

C27

GyB (266) C01

3RD SPEED SOLENOID VALVE

(144)(LW)

B24

REVERSAL FAN INDICATOR LAMP (OPT)

(RL)(235)

E27

SbY (172) E22

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR (OPT)

(143) LO

C26

SbY (171) E30

BRAKE OIL PRESS. SENSOR 2

D14

CAN

S2S

B07

C03 F13

D02 D16 A21 A29 A14 D21 A28 D01

C16

BrY (181) BrY (181)

E09 (+5V) E34

AIR TEMP. PROBE

A19 A15 A16 A27

Gy (750)

C08

A24

E19

D26

A05

A32

TO E/G SPEED SENSOR TO THROTTLE SENSOR

(LY)

GyW (200) C23 GL (265) GL (265) C22 GyW (260) C33

(163) (SbW) (005-b) (L)

B13 D05

D09

GO (164)

OFF

KO BS

C09

B09

D12

D08

PARKING SOL (162)

A03

D25

(LgY) (167)

(273)

MCU FAILURE RELAY

OPT

C31

LOWER KICKOUT S/W REVERSAL FAN S/W (OPT) AUTO FAN E/G REVERSAL S/W (OPT) SPARE SECONDARY SPARE STEERING PUMP (OPT) OPTION 1 OPTION 2 E A/M SELECTION ODOMETER SELECTION SPEED SENSOR SELECTION METER SELECTION

YO (176)

DECLUTCH S/W

D24

(210)

BrB (258)

NEUTRAL RELAY

(YL) (124)

DECLUTCH SET-UP

(720) GLOW LAMP (BG)

CAB

B10

LgW (101)

(LO)

FUEL PUMP

GLOW PLUG RELAY 100

B11

D04

(SbP) (145)

D07

10A

(015) WR

D11

D06

SHIFT HOLD S/W (OPT) (011) WB

F11

B18

(LG)

SAFETY RELAY (707) WL

(709) [R8]

YW (233) R

CHARGE LAMP 70A

YO (232)

(708) WP

F13

MACHINE

LW (120) LO (123)

70A

F14 (014) G1.25

LBr (128) F N R

(700) WV

(063) WR1.25 10A

(064) G1.25

(708) WP

(015) WR

E04 E12 E03 E11

B12 LR (126)

SHIFT LEVER

(065) WR1.25 F15

R1 BR B AC R2 C

E24

A12

(LgR) (130) (GR) (135) (GyB) (103) (LgY) (173) (O)

(013) (Lg)

AUTO SHIFT INDICATOR LAMP NEUTRAL INDICATOR LAMP CENTRAL WARNING LAMP BRAKE OIL PRESS. WARNING LAMP

(241)

(GyG)(753)

E/G COOLANT TEMP. WARNING LAMP

(GyL) (190)

T/M OIL TEMP. WARNING LAMP

(LgW)(192) (O) (241)

AIR CLEANER WARNING LAMP STEERING OIL PRESS. WARNING LAMP

A20 C11 A30 C06

FUEL EFFICIENT MODE S/W

E EFFICIENT LOADING SYSTEM S/W (OPT)

RIDE CONTROL S/W (OPT)

3A X

MCU FAILURE

FUEL LEVEL GAUGE

15A

ECM

20A

36 30A

(LgW)(102)

This page illustrates the transmission is in neutral and key switch is in OFF position.

(404)(YBr) (LgSb)(112)

WARNING BUZZER

65ZV2/TMV2-09708-06251 USA 1/2

65V2U92005

65ZV-2 US 92-31 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 5001~5050)

Electrical Connection Diagram (2/2) (S/N 5001~5050) ! /

)

& ! &

(

!"!

$& &* * $& &* *

! +

# #(

(

)

& !

& + # #( !

& + # #(

$ ( ( ! &*

!&& *)

# & * )

# & * #

!"#

# &

& & & # * (

(

!"#

+ & &

)

# )

'!"

# ) ' '

#%!

# 0--12.,0- ,3'"34 *

! (

#( # *

& ! & &

( & &

+ #

* & &

$ *

#( $ & # *

#( # *

$ $ & # *

#( &

$ # *

& &

#%!

$ # *

( & &

& & * )

! & + # #( &*

$ (

! & + # #( &*

! + * *

! & + # #( #%

! + * *

#( ! + *

+ &* ! &

# *& &

! & + # #(

* ( ! ,-.

$ ! + *

! '

&& *

! + *

!&& * )

* & &

& ! #% & + # #(

& + # #(

' & + # #(

!&& *)

& & + # #(

$ & & + # #(

+ *) &

& $ & & + # #(

$ & & + # #(

& + # #( *

$ ( #(

$ & & + # #(

& & *( * ) &

# & * )

(

#( ( #(

' #%

)

$ ( #( (

$ * *

# && *)

(

#( ( #( (

) & * &

& ! & (

$ *)

(

( #( ! *

$& + *& &

& & &

! +

* #( #

)

# )

$ &

$& &* *

!&& + + &

(

# & + !

This page illustrates the transmission is in neutral and key switch is in OFF position.

(& (& & & && * &

65ZV-2 US 92-32 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 5051~5100)

Electrical Connection Diagram (1/2) (S/N 5051~5100)

STARTER S/W B

BR ACC R1 R2

ACC’

(L) (005-b)

C F5

PREHEAT OFF ON START

(005) L2

(L) (005-a)

30A G (010)

F10

Lx4 (005-A~005-D)

ACC’ (086) [W3]

(900) [W5]

12V

100

30A

12V

E05 E06 E17 WL (707)

BATTERY ECM (V24) (065) WR1.25 F15

R1 BR B AC R2 C

15A

F N R

BATTERY RELAY

F13

STARTER

(013) (Lg) 70A

F14

10A

(014) G1.25

LR (126)

(700) WV

(063) WR1.25

23A

(701) [R5] (703) RL1.25

(702) [BW5]

B R

(706) WL1.25

F/R SELECTION S/W (OPT)

(707) WL

(709) [R8]

70A (723) [BR5]

70A

R R1.25 (710) ALTERNATOR

YW (233) R

(011) WB

(711) BrL

FUEL PUMP

F13 (725) [BR5]

(015) WR

GLOW PLUG

ECM(V10)

GLOW PLUG RELAY M

100

TO PILOT LAMP ACC’

B E

F13 DECLUTCH

(013) (Lg)

SHIFT INPUT SELECTION S/W (OPT)

YV (231)

ARM WREST S/W (OPT)

(YL) (124) (YL) (124)

DOWNSHIFT S/W

YSb (125) LP (168)

DECLUTCH SET-UP

LIFT KICKOUT SET-UP

BrG (255)

LOWER KICKOUT SET-UP

BW (271)

MACHINE

CAB

15 15A

30 20A

14 10A

29 20A

28 10A

PARKING SOL (162) LgG

Lg (222) LgY (223) (Y) (105) (R) (106) P (107) PL (108) PG (109) PB (110)

D10 D19 D26

D18

LLg (165)

E/G OIL PRESS. S/W

PARKING S/W

MCU FAILURE RELAY

LIFT KICKOUT RELAY LOWER KICKOUT RELAY

B04 A18

YGy (242)

SECONDARY STEERING MOTOR RELAY COIL (OPT)

LR (146)

F SOLENOID VALVE

LBr (148)

R SOLENOID VALVE

(141) LY

1ST SPEED SOLENOID VALVE

A02

(142) LG

2ND SPEED SOLENOID VALVE

A05

(143) LO

3RD SPEED SOLENOID VALVE

Gy (750) BrY (181)

HYD. OIL LEVEL S/W

LgL (182)

AIR CLEANER CLOGGING S/W

A08

(144)(LW)

4TH SPEED PILOT LAMP

D24 A17

11 10A

10 15A

25 20A

15A

24 10A

15A

23 10A

10A

15A

21 15A

30A

20 10A

15A

19 10A

10A

15A

ECM

20A

36 30A

FUEL EFFICIENT MODE S/W

A32

C08

A24 B09

D17 D15 D23 D22

C34 C30

TO E/G SPEED SENSOR TO THROTTLE SENSOR

A07 A04 A01

C13

C25

V (100)

B14

B06

E02

RIDE CONTROL SOLENOID VALVE (OPT) EFFICIENT LOADING SYSTEM SELECTION SOL. VALVE (OPT)

LgL (261) GB (267) LgL (225) (226) LgB

(221) LgB 1A

BrR (251)

DECLUTCH SENSOR BRAKE OIL PRESS. SENSOR 1

FAN SPEED CONTROL SOL. VALVE

BRAKE OIL PRESS. SENSOR 2

LgR (166)

SECONDARY STEERING OIL PRESS. SENSOR (OPT)

SbR (240)

B07

GyB (266)

C03 D02 D16

D21 D01

C16 C11

A21 A29 A14 A28 A19 A15 A16 A27 A12 A20 A30

C06

(LgR) (130) (GR) (135) (GyB) (103) (LgY) (173) (O)

(241)

(GyG)(753)

AUTO SHIFT INDICATOR LAMP

GyL (180)

T/M OIL TEMP. SENSOR

NEUTRAL INDICATOR LAMP

AIR TEMP. PROBE

CENTRAL WARNING LAMP

HYD. OIL TEMP. SENSOR

(G) (415) GyO (220)

BRAKE OIL PRESS. WARNING LAMP E/G COOLANT TEMP. WARNING LAMP

(GyL) (190)

T/M OIL TEMP. WARNING LAMP

(LgW)(192)

AIR CLEANER WARNING LAMP STEERING OIL PRESS. WARNING LAMP

(O) (241)

GyG (754)

E/G COOLANT TEMP. SENSOR

(013) (Lg)

BY (114)

S3W S3R

E/G SPEED SENSOR ECM(V8)

MACHINE SPEED SENSOR

B24

E10

E26

A06

C01 B25

A10 E31

B19

LgBr (104)

S/S INDICATOR LAMP (OPT) BUZZER

(YB ) (401)

E/G COOLANT TEMP. GAUGE

(BrW) (402)

T/M OIL TEMP. GAUGE

(400) )(WL

METER OUTPUT (TACHOMETER)

(420) (+) OL

(−)

(421) (+) OB

(−)

TACHOGRAPH E/G SPEED (OPT) TACHOGRAPH GROUND SPEED (OPT)

YSb (403)

(LB) (138) (RG)(331)

HOUR METER DRIVE

E TO BACK-UP LAMP TO BRAKE LAMP

E32

(100) V

(E09) E23 E07

B23(OUT_FEW) E33(OUT_RES) E25(RXD0) B26(TXD0) B17(OUT_MD2)

(115) (YB) (116) (YG) (117) (YL) (118) (YO) (119) (YBr)

C18

+5V FEW RESET RXD TXD MD2 GND

E15 E16

(CANH0)E29 (CANL0)E20

GL (810)

RS232C

GR (811) S2H S2L S2H

E08

S2L

MCU PROGRAM REWRITE (For factory use only)

E (RIN1)B16 (DOUT1)B22

Y (160)

(LgB) (224)

C27

V (100) W (161)

REVERSAL FAN INDICATOR LAMP (OPT)

(RL)(235)

E27

S3B

THROTTLE OPENING SENSOR

(E09)

C26

SbY (172) E22

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR (OPT) F13

E21

SbY (171) E30

E01

C12 C02

E19

BOOM ANGLE SENSOR

REVERSAL FAN SOL. VALVE (OPT)

E09 (+5V) E34

Y (159)

12 15A

C09

D14

GyW (200) C23 GL (265) GL (265) C22 GyW (260) C33

(273)

NEUTRAL RELAY

(LY)

D09

(163) (SbW)

OFF

D03

D08

DECLUTCH

(005-b) (L)

D05

D25

GO (164)

OFF ON

D12

C31

(LgY) (167)

(LO)

YO (176)

DECLUTCH S/W

BrB (258)

(LG)

(210)

LgW (101)

D07

FP (720) GLOW LAMP (BG)

B10

(SbP) (145)

OPT

D06

SHIFT HOLD S/W (OPT)

10A

YO (232)

SAFETY RELAY

CHARGE LAMP

D04

B11

LW (120)

(708) WP

F13

D11

B13

LY (121)

[R5]x6 (910~ 915)

(724) [BR5]

B18

A03

LG (122)

LBr (128)

LO (123)

F11

E04 E12 E03 E11

B12

(708) WP

(015) WR

E24

SHIFT LEVER

(060) (901) W [W5]

(064) G1.25

TO PARKING S/W

MAIN MCU

CAN

S2S

EFFICIENT LOADING SYSTEM S/W (OPT)

RIDE CONTROL S/W (OPT)

3A X

MCU FAILURE

FUEL LEVEL GAUGE

(LgW)(102)

(404)(YBr) (LgSb)(112)

WARNING BUZZER

This page illustrates the transmission is in neutral and key switch is in OFF position. 65ZV2/TMV2-09708-06390 USA 1/2

K65V2U92013

65ZV-2 US 92-33 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 5051~5100)

Electrical Connection Diagram (2/2) (S/N 5051~5100) %

' " '

" !

)

"#" !

%' '+ + %' '+ +

" !

"# !

! "#

+ $) $

$ '' +*

$ $)

)

$) ) $) )!

% ' ' $ $) *

' "

$& !

' $ $) '

' $ $)

$ !

% !

! $

! '

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This page illustrates the transmission is in neutral and key switch is in OFF position.

65ZV-2 US 92-34 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 5101~5400)

Electrical Connection Diagram (1/2) (S/N 5101~5400) STARTER S/W

ACC’

B BR ACC R1 R2 C

F5 (086) [W 3]

OFF ON START

30A

(900) [W 5]

12V

(060) (901) W [W 5]

WL (707)

(700) WV

LR (126) LBr (128) F

F13

F14

10A

N R

STARTER

BATTERY RELAY

(013) (Lg) 70A

(014) G 1.25

[R 5 ]x6 (910~915)

(701) [R 5 ] (703) RL1.25

LG (122) LY (121)

SAFETY RELAY

F/R SELECTION S/W (OPT)

(708) WP

(705) WG

LW (120) LO (123)

(706) WL 1.25 F13

2 3 A

(702) [BW 5] B

YO (232) YW (233)

70A

R 1.25 (710)

(011) WB

F11

F13

B R

ALTERNATOR (711) BrL

FUEL PUMP

(720) (BG)

GLOW LAMP

YV (231)

ARM WREST S/W (OPT)

LB (230)

DOWNSHIFT S/W

(YL) (124) YSb (125) LP (168)

DECLUTCH SET-UP

(210) BrG (255)

LIFT KICK OUT SET-UP

ECM(V10)

GLOW PLUGRELAY

SECONDARY STEERING PUMP (OPT)

ACC’ TO PILOT LAMP BACK LAMP

BW (271)

LOWER KICK OUT SET-UP LOWER KICK OUT S/W

E/G

REVERSAL FAN S/W (OPT)

Lg (222)

AUTO FAN REVERSAL S/W

LgY (223)

NEW INCHING SELECTION (R) (106)

NEW ECO MODE SELECTION (OPT)

F13

20A

10A

15A

10A

15A

20A

15A

10A

15A

10A

15A

30A

10A

15A

10A

15A

20A

PARKING SOL

BrB (258) L

(273)

(162) LgG

NEUTRAL RELAY

MCU FAILURE RELAY LIFT KICK OUT RELAY LOWER KICK OUT RELAY

KO BS

D05

B04

D03 D10

A18

YGy (242)

SECONDARY STEERING MOTOR RELAY COIL (OPT)

LR (146)

F SOLENOID VALVE

LBr (148)

R SOLENOID VALVE

(141) LY

1ST SPEED SOLENOID VALVE

(LY) D19 A02

(142) LG

2ND SPEED SOLENOID VALVE

D26

A05

(143) LO

3RD SPEED SOLENOID VALVE

D18

(013) (Lg)

A/M SELECTION

PG (109)

ODOMETER SELECTION

PB (110)

SPEED SENSOR SELECTION

GyW (200) GL (265) (GyW) (260) EP

E/G OIL PRESS. S/W (005-b) (L)

OFF

PARKING S/W

4TH SPEED PILOT LAMP

A17

A32

D14 B14

A24

A07

B09

D17 D15 D23 D22

A04 A01

C13 B06

C25 E02 C34

RIDE CONTROL SOLENOID VALVE (OPT) EFFICIENT LOADING SYSTEM SELECTION SOL. VALVE (OPT)

LgL (261) GB (267) LgL (225) (221) LgB

(226) LgB 1A

HYD. OIL LEVEL S/W

BrY (181)

AIR CLEANER CLOGGING S/W

LgL (182)

E34

E21

BOOM ANGLE SENSOR DECLUTCH SENSOR

FAN SPEED CONTROL SOL. VALVE

BRAKE OIL PRESS. SENSOR 1

BrR (251)

(LgR) (166)

F13

D02 D16 A21 A29 A14 D21 A28

(LgR) (130) (GR) (135) (GyB) (103) (LgY) (173)

D01 A19 C23 A15 C22 A16 C33 C16

A12

C11

A20

C06

A30

(GyG) (753) (GyL) (190) (LgW) (192) (O) (241)

SbR (240)

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR (OPT)

(013) (Lg)

AUTO SHIFT INDICATOR LAMP NEUTRAL INDICATOR LAMP CENTRAL WARNING LAMP BRAKE OIL PRESS. WARNING LAMP E/G COOLANT TEMP. WARNING LAMP T/M OIL TEMP. WARNING LAMP AIR CLEANER WARNING LAMP STEERING OIL PRESS. WARNING LAMP

GyB (266)

E/G COOLANT TEMP. SENSOR T/M OIL TEMP. SENSOR AIR TEMP. PROBE

GyG (754)

HYD. OIL TEMP. SENSOR

GyO (220)

GyL (180) (G) (415)

BY (114)

THROTTLE OPENING SENSOR

C09

S/S INDICATOR LAMP (OPT) BUZZER

(YB) (401)

E/G COOLANT TEMP. GAUGE

(BrW) (402)

T/M OIL TEMP. GAUGE METER OUTPUT (TACHOMETER)

(WL) (400)

E26

(420) OL

(+)

(−)

TACHOGRAPH E/G SPEED (OPT)

(421) OB

(+)

(−)

TACHOGRAPH GROUND SPEED (OPT)

C27

A06

C01 B25

A10

E31

B19

E32 B19 E23

YSb (403)

(LB) (138) RL (245)

(100) V

(E09)

S3B

B23(OUT_FEW)

S3W

E33(OUT_RES) E25(RXD0) B26(TXD0)

BACK-UP LAMP

BRAKE RELAY (ZV: S/N 5127~, RG (331) TO BRAKE LAMP TMV: S/N 4065~) (ZV: S/N ~5126, TMV: S/N ~4064) E

E07

C18

HOUR METER DRIVE

(115) YB

E/G SPEED SENSOR MACHINE SPEED SENSOR

+5V FEW

(116) YG

RESET

(117) YL

RXD

(118) YO

TXD

(119) YBr

MCU PROGRAM REWRITE

MD2

V (100)

C08

E10

S3R

ECM(V8)

FUEL EFFICIENT MODE S/W

B24

B17(OUT_MD2) (E09)

LgBr (104)

E27

SbY (172) E22

SECONDARY STEERING OIL PRESS. SENSOR (OPT)

REVERSAL FAN INDICATOR LAMP

(RL) (235) (LgB) (224)

C26

SbY (171) E30

BRAKE OIL PRESS. SENSOR 2

B07

E09(+5V)

E19

C12

A27 Gy (750)

V (100)

TO E/G SPEED SENSOR TO THROTTLE SENSOR

REVERSAL FAN SOL. VALVE

E01

D09 LLg (165)

(163) (SbW)

(144) (LW)

D24

D08

METER SELECTION GO (164)

OFF

A08

C03

T/M CUT OFF

DECLUTCH S/W ON

10A

D12

C02

(LgY) (167)

B13

C30

YO (176)

20A

A03

D25

CAB

B10

LgW (101)

OPT

C31

OLD ECO: Connec NEW ECO: Open

DECLUTCH

D04

B11

(SbP) (145)

(LG)

SHIFT INPUT SELECTION S/W (OPT)

GLOW PLUG

15A

B18

(LO)

(725) [BR 5 ]

100

E04 E12 E11

SHIFT HOLD S/W (OPT)

(724) [BR5 ]

MACHINE

E03

D07

10A

D11

D06 (709) [R 8]

(723) [BR 5 ]

E17

(707) WL

CHARGE LAMP

(015) WR

E24

E06

B12

(063) WR1.25

(064) G1.25

L x4 (005-A~005-D)

E05

15A

TO PARKING S/W

BATTERY (708) WP

(015) WR

(005-b) (005-a)

G (010)

F10

ACC’

ECM(V24) (065) WR1.25 F15

R1 BR B AC R2 C

(L) (L)

30A

12V

100

SHIFT LEVER

PREHEAT

(005) L5

GND

E W (161) Y (160) Y (159)

(RIN1)B16

E15

(DOUT1)B22

GL (810)

RS232C

GR (811)

E16 E08

(CANH0)E29 (CANL0)E20

EFFICIENT LOADING SYSTEM S/W

S2H S2L

RIDE CONTROL S/W MCU FAILURE

ECM 36

30A

FUEL LEVEL GAUGE WARNING BUZZER E

(LgW) (102)

This page illustrates the transmission is in neutral and key switch is in OFF position.

(404) (YBr) (LgSb) (112)

CAN

S2S

Option in MAIN MCU

BZ 65ZV2/TMV2-09708-06511 1/2

K65V2U92021

65ZV-2 US 92-35 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 5101~5400)

Electrical Connection Diagram (2/2) (S/N 5101~5400) ACC’

E F1

ACC’

COMBINATION S/W

(001) R 1.25

RB (301)

20A

RY (302)

BrB (257)

Br (003)

BOOM KICK-OUT

10A

ECM(V21) (V40)

LH EL

RW (304)

E F3

HU BrR (272)

LICENSE LAMP

V81

V43

BUCKET LEVELER FORK POSITIONER

BrY (253)

TAIL LAMP

WR (015)

OY (007)

10A

INSTRUMENT PANEL LIGHTING

F20

AIR-SUS. COMPRESSOR

V6 (YO) (748)

V32 V7

E ATOMOSPHERE PRESS. SENSOR

(VW) (765)

INTAKE AIR TEMP. SENSOR

GyL (767)

GL (766)

BP (768)

V61

V11

V71 V72

V21

10A

MODM

S2L

HIGH BEAM PL

(307) (RY)

(305) UL RY

(308) RW (006) RG 1.25

FRONT WORKING LIGHT S/W

FRONT WORKING LIGHT FRONT WORKING LIGHT

RLg (521)

(002) R 1.25

F2 15A

TO CAB WORKING LIGHT

F13

RESISTOR

TO FRONT WORKING LIGHT TO REAR WORKING LIGHT

RGy (520)

CAB WORKING LIGHT CAB REAR WORKING LIGHT CAB REAR WORKING LIGHT

REAR WORKING LIGHT

10A

(501) Y (502)W

WORKING LIGHT RL(330) BACK-UP LAMP

RIGHT BRAKE LAMP

(S/N 5127~, 4065~) F4

(004) R

WASHER MOTOR (500) PB M F18

LEFT BRAKE LAMP

15A

ACC’

B L

(320) COMBINATION (325) P S/W (321) RO RO TR (322) TB RBr TL (060) W

F10

(010) G

FLASHER UNIT (HAZARD)

15A

(327) RBr (326) (RBr)

EGR POTENTIOMETER U V

F22

RIGHT FRONT TURN SIGNAL PL

LEFT FRONT TURN SIGNAL PL LEFT REAR TURN SIGNAL PL LEFT TURN SIGNAL PL

HORN S/W HORN RELAY TO ROOM LAMP TO MCU (E17) E

HORN

S5S S4S S5W

S6S S6W S6B

V37

E/G OIL PRESS.

(716)

BrG

(722)

(758)

S2H

S2L

(PL)

V52

(YL)

(747)

BrG

(738)

14 7

E91

E111

E93

E103

E92

E110

E82

E101

E119 E117 E116

E100

E118

E99

E120

YW 1.25 (789)

YR 1.25 (790)

YL 1.25

(791)

E105

E107

E113

E106

E89

E/G

F27

EGR

10 36

11 34

23 16

F28 10A

RY 2

(BR) (BrW) (WY)

A/M SERVO MOTOR

(WR)

MAM

(OL) (GO)

RIGHT VENT SELECTION SERVO MOTOR

(Sb)

MV1

(WG) (LgY)

LEFT VENT SELECTION SERVO MOTOR

(BrB)

MV2

(WP) (VW)

DEF SELECTION SERVO MOTOR

(YB)

MV3

INSIDE/OUTSIDE AIR SELECTION SERVO MOTOR

(BG) (PB)

(V)

MRF SP HL

(LgR) (BL)

SP CD

(LgW)

BLOWER MOTOR

1 BLC

G 1.25

RY1.25 RG

EC C

COMPRESSOR CLUTCH

RG1.25 (794)

1.25

RW CD

MCD

1.25

R CD

CONDENSER MOTOR CH

LgBr

(792)

CYLINDER1

LgW

(793)

CYLINDER4

ACC’

RG 1.25 (797) LgR

(795)

CYLINDER2

LgY

(796)

CYLINDER3

GyR

(798)

GyB

(799)

E98 E108

20A

(PL)

RY1.25

E94

9 24

F29

E109

AC M

E95

E87

DATA LINK CONNECTOR

INSOLATION (SS) SENSOR

OUTSIDE AIR SENSOR (THAM)

CAN

(BrR)

S2L V38

WATER TEMP. SENSOR (THW) (Y)

S2S

S2H

BLOW-OFF THERMISTOR (THF) (BY)

GLOW RELAY TO CONTROLLER (E/G SPEED)

V79

INSIDE AIR SENSOR (THI) (P)

MAIN RELAY

V67

(GW)

V80

V74

(RB)

(BR)

(726) GLOW LAMP RELAY (BR) GL YB

F13 NIGHT ILLUMINATION

E97

R WIPER

BOOST TEMP.

(749) (Gy)

(BrY)

SCV

E/G

ECM

GR (508)

S1 S2

WASH

RADIO POWER RELAY CIGER SOCKET (24V) POWER RELAY

CONVERTOR (060) ACCESSORY W2 15A

(328) (GL)

(WBr) (022)

ACC’

(323) BP

(329) GW

S4R

(732) (BrW)

WIPER S/W

RIGHT TURN SIGNAL PL RIGHT REAR TURN SIGNAL PL

CRANK ANGLE 6

(507) GY

E84

V18

E121

S5B

WIPER MOTOR M

YL (779)

S4B CAM ANGLE

E WASHER MOTOR (506)

YR (778)

E83

E90

YW (505) 5

YW (777)

F WIPER

L (503)

(018)

(OPT)

FLASHER UNIT (WINKER) (324)(RO)

VR (774)

BLg (776)

WIPER S/W

(504) LY

GW (764)

S4W

S 2 S3 B WASH S int S 1

BACK-UP ALARM (331) RG

TO MCU (B19)

VR (771)

GB (775)

WIPER MOTOR OR (019)

BACK-UP LAMP (ZV: S/N ~5126, TMV: S/N ~4064)

BOOST TEMP.

CAB WORKING LIGHT

RGy (520) TO CAB REAR

GyR (770)

BG (773)

ROOM LAMP

F19

GR (769)

Gy (772)

RLg (521)

REAR WORKING LIGHT

(013) Lg

E/G OIL PRESS.

COMMON RAIL PRESS.

RGy (312)

REAR WORKING LIGHT S/W

CANL0

BOOST PRESS.

WORKING LIGHT PL RLg (311)

CANH0

G (010)

F10

LEFT HEADLIGHT (L)

(310) (RGy)

15A

E/G COOLANT TEMP.

S2L S2S

RIGHT HEADLIGHT (L)

GND

S2H

CAN

RIGHT HEADLIGHT (H) LEFT HEADLIGHT (H)

(306) RY

V8 FUEL TEMP.

KEY

(013) (Lg)

WARNING

(LO)

E (730) (BrR)

6 BM

V40

V60 V10

S2H

(RL)

MEMORY CLEAR S/W

O (020)

TO AIR CONDITIONER

F26

V24

V17

BrW (250)

(252) BrW

TAIL LAMP

ACC’

V62

BUCKET LEVELER

65TMV-2

MACHINE WIDTH LAMP

FUEL PUMP RELAY

MAIN RELAY

F15

MACHINE WIDTH LAMP

(715) YL1.25

B BrW (250)

FOR OPT LAMP

(RB) (300)

(036) G1.25

30A

65ZV-2

(OPT)

FOR OPT LAMP

RB (303)

F36

FLOAT

(716) YB

AIR CONDITIONING UNIT

(531) Y2 I N

O U T

P1.25 (514)

DC-DC CONVERTOR

B3 B4

(511)GyB

This page illustrates the transmission is in neutral and key switch is in OFF position.

A7 A4

A8 B6 (532) W2

(510) Gy

(512) WR (513) WB

CIGER SOCKET (12V) CAB E

Option in

65ZV2/TMV2-09708-06511 2/2

K65V2U92022

65ZV-2 US 92-36 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 5401~)

Electrical Connection Diagram (1/2) (S/N 5401~) # # !

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This page illustrates the transmission is in neutral and key switch is in OFF position.

+:;<67 <7

65ZV-2 US 92-37 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 5401~)

Electrical Connection Diagram (2/2) (S/N 5401~) ! '% ' % + &

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This page illustrates the transmission is in neutral and key switch is in OFF position.

' %

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65ZV-2 US 92-38 92 Drawing & Diagrams Electrical Connection (Cabin Air Conditioner) (S/N 5001~5050)

Electrical Connection (Cabin Air Conditioner) (S/N 5001~5050)

36505-60080 BER868952

36505-60090 BER868951

DUCT ASSEMBLY

DUCT ASSEMBLY 5 6 7 8 9 10

650650

LOW PRESSURE SWITCH C11

HIGH PRESSURE SWITCH C12

PKD 12052644

A B

BER650712

VEHICLE HARNESS C8

33191-60530

+24 VDC

C3 1 2 3 4 5 6 7 8 9 10 11 12

33435-60270 33435-60290

CONTROL

HARNESS +24 VDC

Transistorized GND

CON12

COND FAN COND FAN A/C FUSED

Protected +24 VDC

C4 HPD24-24-21PN A B C D E BLWR SPD F G H WV SIG J K L M +24 VDC N P R S T U V W X

33191-60520

33191-60540

HARNESS

HDP26-24-21SN A 12V GND B C +BATT 24V D A/C_COMP E BLOWER SPEED F COND_RLY G H WV SIG J A/C REQ K A/C COMP L M EVAP_TEMP N P R S T U V 12V_2 W X

+24 VDC

HDP26-24-21SN 12V A GND B C D PWR1 E BLOWER SPEED F G H WV SIG J A/C REQ K A/C COMP L M EVAP_TEMP N P R S T U V 12V 2 W X

C15

+24 VDC

1 2 3 4 5 6 7 8 9 10 11 12

Ground

+24 VDC

A method to determine if the controller is causing actuators to be unresponsive is to disconnect the controller and see if the actuators will automatically center themselves. If not, there is another issue. If so the controller may be the cause. If the actuators on left side do not work, there may be a 12V supply problem at PWM2. Pin 5 of PWM2 is the 12 VDC power supply for the left side actuators. If the actuators on right side do not work, there may be a 12V supply problem at PWM1. Pin 5 of PWM1 is the 12 VDC power supply for the right side actuators and heater control actuator. Check this also if there is a heat actuator problem.

C18

CONDENSOR RELAY

A/C_COMP A/C_FUSED

A/C CLUTCH FUSE (See upper left corner)

+24 VDC

PKD 12085030

Ground

PKD 12033871

C14

BER203208

BLOWER MOTOR 2

87a

+24 VDC

Ice Cube Relay detail

C16 1 2 3 4 5 6 7 8 9 10 11 12

33435-60280

PWM 2 DT06-12SA-EP07

Pin 5 - +12 VDC out Pin 7,8,9 - Motor square wave

* By bridging between terminals at lp circ. s/w, continuity should be established between terminals K and L.

C19 30 85 87A 87 86

45050-60080

POWER RELAY 2 PKD 12033871

45050-60080 PKD 12033871

C20 A/C RELAY

Coil

The chassis ground is black.

1 2

45050-60080

POWER RELAY 1

DT06-2S-EP06

VF4-15F13

DT06-12SA-EP07

Pin 2 - Motor speed control

87A

45050-60070

PWM 1

30 85 87A 87 86

Protected +24 VDC

A B 85 86

33435-60280

Pin 5 - +12 VDC out Pin 7,8,9 - Motor square wave

LS1 30

BER203208

BLOWER MOTOR 1

Pin 2 - Motor speed control

+24 VDC

Note: When evaporator fans do not run or run only at low, if controller is disconnected and the fan speed rises, the controller is suspect.

PKD 12065686

C17 1 2

30 85 87A 87 86

PKD 12040953

COND_RLY

COND_FAN

COND_RLY

RIGHT BOTTOM ACTUATOR

30 85 87A 87 86

PKD 12040953

5 6 7 8 9 10

30 85 87A 87 86

C1 LEFT BOTTOM ACTUATOR

PKD 12040953

DT06-2S-EP06

HARNESS

HD34-24-21PN A B C D E F G H J K L M N P R S T U V W X

+24 VDC

5 6 7 8 9 10

BER868708

WATER VALVE

To compressor clutch

+24 VDC

+12 VDC

5 6 7 8 9 10

Ground

DT04-08PA-E004

1 2 3 4 5 6 7 8

PKD 15300002

PKD 12040953 GND

PKD 12040953

RIGHT TOP ACTUATOR 1

5 6 7 8 9 10

LEFT TOP ACTUATOR

GROUND LUG GND

35829-60120

FREEZE SWITCH C9A C10B

Note: Thermal switch connects to "A" and "B" to the right & is equipped with a small capillary line that contains ether. Refer to "Evaporator thermal switch" page in Section 72 for the function.

Note: The system uses a 5 amp fuse for the A/C clutch circuit that is located in the right side relay box. This fuse is not in the fuse group along with the other fuses. It is typically found toward the rear of the box low in the wiring and has a dark cover.

BER650713

A B

Kawasaki / Bergstrom HVAC Manually Operated System

K65T2U92011

65ZV-2 US 92-39 92 Drawing & Diagrams Electrical Wiring Diagram (Cabin Air Conditioner) (S/N 5051~)

Electrical Wiring Diagram (Cabin Air Conditioner) (S/N 5051~) Control panel

Illumination power supply

24V(BR')

Fuse box 26

F26

RB A401 RL B408

RG B409

RB B417

R B418

Outside air sensor (THAM)

Condenser relay (MB)

Compressor clutch relay (RLEC)

Condenser HI relay (RLCH)

RB BrY B417 B307

RG BrY B409 B307

Y B B415 B410

RW RL B416 B408

YR RL B407 B408

B LgW B410 D104

5A YB LgY VW A403 A604 A605

B BR A501 A509

BrR Y BY P GW WP WG OL A102 A611 A609 A606 A608 A506 A502 A503

BG RL RB LgR PL BrW A612 A401 A507 A101 A504 A505 A508

BL A510

Sb GO PB V WY WR LO BrY BrB A402 A404 A405 A603 A602 A601 A406 A607 A610

F27 5A F28

10A

F29

Insolation sensor (SS)

BR Y A509 A611

20A

(Black)

A4 1

Sb GO WR B304 B303 B302

LgY BrB RB A220 A210 A305

RB BrB LgY A801 B312 B311 1

BL BR PL LgR WP A308 A211 A303 A304 A311

Floor harness

LO GW BY BrY Y RL B310 B309 B308 B307 A901 B315

PB V VW YB WY P A313 A218 A219 A207 A206 A205

WY V PB YB VW P B320 B319 B318 B317 B316 B314 1

R RB RW Y A704 A703 B101 B102

BrY BY GW LO B503 C601 C501 C903 B603 P RL VW YB PB V WY LgY BrB LgR C107 C106 D103 D201 C901 C203 C202 C407 C406 B807

BG BL B A505 A510 B103

B RG RL YR PL WG OL BrW BR A702 A701 B202 A508 A502 A503 A504 A509 A501 9

WP WR GO Sb C201 B806 B907 B906

PB VW RL P LgR BrB LgY V YB WY A601 A602 A603 A604 A605 A612 A606 A507 A402 A403

Y BrY BY GW LO RL A306 A315 A202 A314 A312 A203

1 Sb GO WR WP A404 A405 A406 A506

BY BrY LO GW A607 A608 A609 A610

WP LgR PL BR BL B301 B313 B406 A902 B411 B402 B WG OL BrW BG B401 B405 B404 B403 B412

OL WG BG BrW B A301 A302 A309 A310 A212 5

10 3

B D101 1

BL BG C702 C405

RW RB Y R B704 B502 B504 C904

BrW OL WG B805 B905 C105

B803 B903 C101 C204 C401

B801 C403 B901 C502 C103 C602 C205 D202

B702 B703 C701

YR B602

RG B604

Def selection servo motor (MV3) 9

B501 B601 D102

Air mixing servo motor (MAM)

Vent selection servo motor (MV1)

Front vent selection servo motor (MV2)

Inside/outside air selection servo motor (MRF) 7

WP VW YB C203 C202 C201

Connector between floor and rear

BR C205

PL C204

C3 3

Rear harness

C307 C306 C305 VW YB WP

Electric blower condenser

1 1 3

B B410

WY WR BrW B320 B302 B403

PL B406

RW B416

BR B402

GO Sb OL B303 B304 B404 1

PL B406

BR B402

LgY BrB WG B311 B312 B405

BR B402

PB V BG B318 B319 B412

VW YB WP B316 B317 B301

BR PL B402 B406

PL B406

C303 C301 BR PL

Y B415

BR B402

PL B406

High/low pressure SW SP HL

Inside air sensor (THI)

Compressor clutch (ECC)

Blower main relay (RLBM)

BLC

Water temperature sensor (THW)

Blow-off thermistor (THF)

Blower motor (MB)

SP CD 4

1 4

3 2

G RY BL B C801 C802 B411 B410

WR GO Sb A204 A208 A209

YR B407

BrR PL A316 A303

C7 BR GW B402 B309

BR BY B402 B308 1

RL B408 B B401

2 G C704 D302

LgW B701

RY RL D301 B315

RY C703 1

LgR B313

R LO B418 B310

G C801

BR B402

RY C902

P B314 1

95ZVE72020

65ZV-2 US 92-40 92 Drawing & Diagrams Electrical Circuit Diagram (Cabin Air Conditioner) (S/N 5051~)

Electrical Circuit Diagram (Cabin Air Conditioner) (S/N 5051~) SW K 13

10A

FU B

FU A

20A

5A LIGHT SW SIGNAL

M RF

M V3

9 2RY 9 1.25RY

9 2RY

M CD

25 15 26 22

28 15 29 22

225W M V 3A

80W

1.25G

2 +B 6

2G 2G

3 1

1.25RY

FRE

M REC

SP CD

RL BM

2 RL CD

2 RL EC

DEF

GND

RL BM

FOOT

RL EC

RL CD

FU EC

FU CD

GND

39 5

SV 3

M V 3B

25 35

M RFA

M RFB

S RF

9 BLC B 3

RL CH BAT

BLC 01

BLC F

AC M

11 8

1 01

28 G

4 R CD

7 RL CH

0.5B

22 B P

17 TH AM

EC C

14 17

TH W

20 TH I

21 TH F

4 23

21 30

31 M AMB

33 M V 1B

S AM

M AMA

36 36

35 M V 1A

S V1

37 M V 2A

38 M V 2B

S V2

S SD

40W

GND

SHUT

37 15 38 22 Vz

34 22 35 15

GND

FACE

31 22 32 15

FOOT

FACE

GND

Mhot

Mcool

22 01

0.5B

SP HL

01 0.5B

0.5B

M AM

ACM

Air conditioner control amplifier

M AM

Air mixing servo motor

RL CH

Condenser HI relay

BAT

Battery

Blower motor

RL EC

Compressor clutch relay

BLC

BLC (blower linear controller)

M CD

Condenser motor

S SD

Solar insolation sensor

Diode 1

M RF

Inside/outside air servo motor

SPCD

Condenser speed change pressure switch

Diode 2

M V1

Vent servo motor

SPHL

Refrigerant high/low pressure switch

ECC

Compressor clutch

M V2

Front vent servo motor

SWK

Key switch

FU A

Air conditioner fuse

M V3

Defroster selection servo motor

TH AM

Outside air thermistor

FU B

Blower motor fuse

R CD

Condenser motor speed change resistor TH F

FU CD

Condenser motor fuse

RL BM

Blower main relay

TH I

Inside air thermistor

FU EC

Compressor clutch fuse

RL CD

Condenser relay

TH W

Water temperature thermistor

M V1

M V2

Dotted lines indicate the wiring on the machine side.

Frost prevention thermistor

95ZVE72019

65ZV-2 US 92-41 92 Drawing & Diagrams Equipment Operation Table (Cabin Air Conditioner) (S/N 5051~)

Manual (Fully automatic mode is released.)

Fully automatic

Control

Equipment Operation Table (Cabin Air Conditioner) (S/N 5051~) Operation condition Outside air Set temperatemperature ture on control panel

Display on control panel

Cycle status

Key switch

AUTO LED

A/C LED

Outside Inside air air LED LED

Relay LCD

Vent

Set temperature

Blower

Servo motor

Blower Compres- Conmain sor denser

Condenser high

> 30 (86ºF)

18 (65ºF)

High load (under burning sun in spring or summer)



18.5 (65ºF) ~ 31.5 (90ºF)

Normal



Set value

30 (86ºF) ~0



High load

Automatic control



Normal



Frost cut



High pressure cut



Low pressure cut



High pressure error



Normal



32 (90ºF)

Before engine is warmed Water temperature < 25ºC



Before/after engine is warmed Water temperature > 55ºC



35 (95ºF) ~0

18.5 (65ºF) ~ 31.5 (90ºF)

Automatic control

Set value



Mode just before OFF is displayed.

Nothing is displayed.



Condenser clogging, etc.

Gas leak, etc.

High/low pressure cut, etc.

Outside air < 0  Fixed to "foot" and compressor disabled

Prevention of cold air blow at low temperature

Set value: 32  High air blow

Set value



FACE /FOOT



or X



FOOT



or X



FOOT /DEF



or X



DEF



or X



Automatic control



or X



or X



or X



Inside air

or X X

(Hi or Lo) X

or X

Automatic control



OFF

(Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo)

A/C manual 

Set value: 18  High air blow

Evaporator frost prevention control

(Hi or Lo)

FACE

Outside air

Outside air > 30  Fixed to "face" (Hi or Lo) Set value: 18  High air blow



Inside/ outside air manual

Remarks

High pressure < 1,226 kPa (12.5 kgf/cm2) (178 psi)

Hi ～ Lo X

Condenser motor

(Lo)

Mode manual

Compressor (clutch)

High air blow

OFF

BLC

High pressure > 1,520 kPa (15.5 kgf/cm2) (220 psi)

OFF

Blower motor

(Hi)

X X

Inside/ outside air

or X

Automatic control

HI ~ Lo

Blower manual

Blow-off

or X

High air blow

OFF

Air mixing

Major functional parts

65ZV-2 US 92-42 92 Drawing & Diagrams Electrical Equipment Layout

Electrical Equipment Layout Front chassis

Bucket leveler (L1)

Head lamp (K0)

Head lamp (K3) To bucket leveler

Ground

Horn (K6)

Width lamp (option)

Boom angle sensor (L3)

To horn

For ride control (option)(L4) (S/N 5015~)

(K1/K2)

Front chassis ground

(K1/K2)

(S/N 5015~) To rear chassis

To rear chassis

(Option)

Black

Red& Light green

Red& Black

(LH) Red& Brown

Black

(RH) Red& Orange

Detail of front lamp wiring

65ZV2-03256-00362US

K65V2U92023

65ZV-2 US 92-43 92 Drawing & Diagrams Electrical Equipment Layout

Front chassis Combination lamp (Option)

Head lamp (K501~K503)

To rear chassis Working lamp (K1, K2)

(K3) Ride control (option)(L4)

(K4)

(L2)

Width lamp (Option)

(L1) Bucket leveler Working lamp

(K6)

Head lamp

(K9)

Combination lamp (Option)

(K0) (K7) (K801~K803)

Horn

Boom angle sensor (L3)

K65V2U92001

65ZV-2 US 92-44 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 5001~5050) E/G glow plug relay (P8)

Safety relay (P7) Parking brake solenoid (M1)

To front chassis To front chassis

Hydraulic oil temperature sensor (L7)

ELS (OPT) (L5/L6)

(H1)

Hydraulic oil level switch (M4)

To floor To floor

To floor ELS (OPT) (L5/L6) (ZV: S/N 5009~) (TMV: S/N 4003~)

(H3~H6) To floor

Engine room

B-B

A-A

To floor ground Rear-Floor ground

Brake oil pressure sensor (M2/M3)

(H3~H6)

Speed sensor (for auto-shift) (M9)

(H2) To floor

To floor

Aircon condenser (L9)

1 poles

Transmission solenoid valve (J1~J5)

Air cleaner (L0) Intake air temperature sensor (J0)

(S/N 5009~)

Washer tank (motor) (M8)

20 poles

Transmission oil temperature sensor (M5) (ZV: S/N 5009~) (TMV: S/N 4003~)

12 poles

Starter ground, Engine ground Starter motor wire

6 poles

8 poles

Alternator (M7) Alternator ground, Rear chassis ground

Starter (P0) E/G harness Rear chassis ground

Reversal fan solenoid (option)

Fuel level sensor (J8)

Compressor (P2)

C-C

To fuel pump

Battery ground Cooling fan speed control solenoid (P1) To radiator guard

Top view

65ZV2/TMV2-03257-00464 US 1/2 K65V2U92028

65ZV-2 US 92-45 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 5001~5050) 20 Red

C Terminal 100 Red 5 BK & Red

Fusible link (spare) Fuse (ECM)

70A

Fusible link (N1) 5 BK & Red 5 White 1.25 White

Fusible 5 link (N2) BK & Red (Red tape) 70A

70A

30A

70A

5 White

5 BK & Red

5 White

1 1 pole pole 5 Red 5 BK & White

To fusible link

Glow plug relay (P8)

( + Mark) B

3 poles

B Terminal E

E Terminal

Rear chassis ground

To ground Starter motor cable

Starter motor wiring

(Red tape) F (P6)

2 poles

4 poles

(Red tape) To rear chassis harness

To rear chassis harness

To alternator

To battery relay

To rear chassis harness

Alternator wiring

5 Red x 6

( + Mark)

To rear chassis harness

5 Red

2 poles

White & Violet

5 BK & White

100 Red

5 BK & Red

Battery relay (N3)

Diode unit (N4)

20 BK

Safety relay (P7)

Starter (P0)

To rear chassis To rear chassis To battery To rear chassis To starter harness harness harness (+)

To rear chassis harness

+ Mark: Connected to red cable Mark: Connected to black cable

Engine relay unit wiring

Fuse (N0)

Rear working lamp connection (N1)

(N2)

Transmission solenoid wiring Rear working lamp (R2) To battery relay

Back buzzer (R4)

Rear working lamp (R3)

(N3) Fan speed control solenoid valve (P1)

To alternator To front

To rear

(P6)

Fuel pump wiring (ZV: S/N ~5008, TMV: S/N ~4002) (N1)

(N2)

Fuel pump (R9/R0)

Diode unit (N4)

To starter To fusible link To front

Oil filter

Fuel filter

Fuel pump wiring (ZV: S/N ~5008, TMV: S/N ~4002)

To battery (+) To rear

Fuse (N0)

Oil filter

To battery relay

Fuel filter

To rear chassis harness

To alternator To front

To rear

Fuel pump wiring (ZV: S/N 5009~, TMV: S/N 4003~)

Battery relay unit wiring

To rear chassis harness

Radiator guard and fan wiring

Fuel pump (R9/R0)

Fuel pump wiring (ZV: S/N 5009~, TMV: S/N 4003~)

65ZV2/TMV2-03257-00464 US2/2

65V2E92013

65ZV-2 US 92-46 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 5051~5200) To floor

(H3~H6) White line

(ZV: S/N ~5118, TMV: S/N ~4060)

(ZV: S/N 5119~, TMV: S/N 4061~)

Brake pipe (H1) Parking brake solenoid (M1)

To floor

(H3~H6)

12 poles

Fan motor hose 6 poles 8 poles

ELS solenoid (OPT)(L5)

Red line

(H1)

Hydraulic oil level SW (M4)

To front chassis

A-A

To front chassis

20 poles

1 pole

Floor harness ELS pressure sensor (OPT)(L6) (ZV: S/N 5101~, TMV: S/N 4051~)

Floor harness ELS solenoid (OPT)(L5)

(Rear

Brake oil pressure sensor (M2/M3)

Speed sensor (Auto shift) (M9)

C-C

To floor

Brake pipe To floor

A (H2)

floor ground)

(H3~H6)

T/M solenoid valve (J1~J5)

Hydraulic oil temp. sensor (L7)

Floor ground

Floor harness

(H2)

Floor harness

Floor harness B

T/M oil temp. sensor (M5)

(H7) C

Washer motor (M8)

Fan motor hose

(Starter Ground) (E/G Ground) B

E/G harness

Air Cleaner (L0)

Starter (P0) (Rear chassis ground)

Cooler fan speed control solenoid (P1)

Alternator (M7)

(Alternator ground) (Rear chassis ground)

Starter motor wire

Compressor (P2)

Intake air temp. sensor (J0)

Reversal fan solenoid (M6)

Fan motor

A/C condenser (L9) To fuel pump Fuel level sensor (J8)

(Battery ground)

To radiator guard

Top view

E/G glow plug relay (P8)

(M0)

Safety relay (P7)

(P5) 65ZV2/TMV2-03257-01167 US1/2

B-B

E/G Room

K65V2U92024

65ZV-2 US 92-47 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 5051~) C Terminal

20 Red 100 Red 5 BK & Red Fusible link (spare) Fuse (ECM)

70A

Fusible link (N1) 5 BK & Red 5 White 1.25 White

Fusible 5 link (N2) BK & Red (Red tape) 70A

70A

30A

70A

5 BK & Red

5 White

Battery relay (N3)

Glow plug relay (P8)

1 pole

Diode unit (N4)

20 BK

To rear chassis harness

To alternator

B Terminal E Terminal

To battery relay

Rear chassis ground

Starter motor cable

Starter motor wiring

White & Violet (Red tape) 100 Red

(P6)

2 poles

4 poles

To rear chassis To rear chassis To battery To rear chassis To starter harness harness harness (+)

+ Mark: Connected to red cable Mark: Connected to black cable

(Red tape) To rear chassis harness

100 Red To rear chassis harness

To ground

To rear chassis harness

5 Red

( + Mark) B

Alternator wiring BK

5 Red x 6

( + Mark)

3 poles

5 Red 5 BK & White

5 White

To fusible link

2 poles

5 BK & Red

1 pole

5 BK & White

2 poles

Safety relay (P7)

Starter (P0)

To rear chassis harness

Rear working lamp connection

Engine relay unit wiring (N1)

(N2)

R Rear working lamp (R2)

Transmission solenoid wiring

Rear working lamp (R3) (N3)

Fuse (N0) To battery relay To alternator To front

Fusible link wiring

Back up alarm (R4)

(P6)

Diode unit (N4)

Reversal fan solenoid (M6) (ZV: S/N 5101~, TMV: S/N 4051~)

Cooler fan speed control solenoid (P1) (M6)

To rear

To battery (+)

To starter

(P1)

To fusible link

To rear

To front

Fuel filter Fuel pump (R9/R0)

(R1)

Fuel filter

To rear chassis harness

Battery relay unit wiring

To rear chassis harness

Radiator guard and fan wiring

Oil filter

Fuel pump wiring 65ZV2/TMV2-03257-01167 US2/2

K65V2U92025

65ZV-2 US 92-48 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 5201~) / ) # # 3- #% 80 -

0 9# 1 < 9 #%

4 9 +#+

/ ' #

2 &1 -#

0 & .

# !+,

) ! 6

2 & % 3 2 2 & %

3 2

.# 5 -

! "#

5 !+ 0

= 9 # !+, :

0 ' # 1 & %

5 / + % ' #% 0

. 1 & % ' # 1 & %

+ % .& #/

/ 7

#% ( ( : 7:

/ 1 & %

4 9 # + &

4 9 +#+ .

$% & #' # !+, -

1 & %

3- + & 80 -

3- #% 80 -

% #

$% & #' # ( ) *

/ ' #

( / #%

. 5 ' % - /& +&!+

& ( :6

4 $ 1 & %

%# 1& %

- ; 7 * ; * 7* 3 2 1 " + &1 $ 06

; * 7 ; * 7

+ (# "

+ 6 +

% ( (

/ $ $ 0 3 2 1 " + &1 $ 06

/ $ $ 0

0 3 2 !

3 2 !

2 &1 -#

65ZV-2 US 92-49 92 Drawing & Diagrams Electrical Equipment Layout

(S/N 5001~5050)

Rear chassis

(S/N 5051~)

Alternator

Aircon condenser Starter motor (P0)

(L9)

Fuel pump (R0)

Alternator

(M7)

Fuel pump

Starter motor (P0) Fuse

(R0)

Fusible link (N2) (N1)

(M7) (R9)

(N0) Battery relay (N3)

Intake temperature sensor (J0) Aircon (L9)

Fusible link (N2) (N1)

Fuse

(J9) (R9)

(N0) Glow relay (P8)

Safety relay (P7)

(P6)

(L0)

Diode unit (N4)

Air cleaner

(N7, N8)

Heater relay (P8)

(J8)

(K1, K2)

(L0)

Diode unit

To floor board (L5) ELS solenoid (option)

ELS pressure sensor (option) (L6)

(N6)

(L8) Fuel level sensor

To front chassis (M2, M3) Brake oil main pressure switch

Parking brake solenoid

(L6) ELS pressure sensor (option)

(N7, N8)

(H3~H6)

To floor board

(K1, K2)

(M2, M3) Brake oil main pressure switch

(J8)

Air cleaner

(L5) ELS solenoid (option)

To front chassis (H1)

(N4)

(N6)

Fuel level sensor

To floor board

(P6)

Safety relay (P7)

(L8)

(H3~H6)

Battery relay (N3)

Intake temperature sensor (J0)

(M1) (H1) To floor board

Parking brake solenoid

(M1)

K65V2U92004

65ZV-2 US 92-50 92 Drawing & Diagrams Electrical Equipment Layout

Rear chassis Working lamp

T/M solenoid valve (J1~J5)

Air compressor (P2)

Combination lamp

(H2) To floor board

(R2) Back-up alarm

Washer motor (OPT)

(ZV: S/N ~5008, TMV: S/N ~4002) E/G water temp. sensor (M6)

Rear chassis (RH) T/M oil temperature sensor

Working lamp

(R4)

(P1)

License lamp (option)

(R6) Cooling fan speed control solenoid

(R3)

(M8) To engine

(Y1~Y5)

Combination lamp Battery

(M5)

(R7)

(H7)

(R1)

To floor board (P5)

(M0) (M9) Hydraulic oil level sensor

(M4) Hydraulic oil temperature sensor

Speed sensor (for auto-shift)

Battery (L7)

K65V2U92005

65ZV-2 US 92-51 92 Drawing & Diagrams Electrical Equipment Layout

(S/N 5055~5100)

Rear chassis

Working lamp

Air compressor (P2)

T/M solenoid valve (J1~J5)

(R2)

To control box

Working lamp

(H2) To floor board

Combination lamp Back-up alarm (R4) Washer motor (OPT)

(P1) Cooling fan speed control solenoid

Rear chassis (RH) T/M oil temperature sensor

License lamp (option)

(R6)

(R3)

(M8) To engine

(M5) (Y1~Y5)

Combination lamp Battery

(H7) (R7) (R1)

To floor board

(P5)

(M0) (M9) Hydraulic oil level sensor

(M4) Hydraulic oil temperature sensor (L7)

Speed sensor (for auto-shift)

Battery

K65T2U92007

65ZV-2 US 92-52 92 Drawing & Diagrams Electrical Equipment Layout

(S/N 5101~)

Rear chassis

6 !! "( #

1) ! , - "4'34 #

"$ #

/ ! , ! ,

"+ # / , !0 "5( #

"$%#

"('#

1) ! !

! " #

"$ #

") #

$ 0 !! ! "$+#

"$*#

") #

") # "2'32 #

"+&#

"$&#

"$'#

/ , "( # ") #

") #

+ , - ! ! ")%# + , ! !

" &#

. , ! ! "/ !0 / #

65ZV-2 US 92-53 92 Drawing & Diagrams Electrical Equipment Layout Floor board (S/N 5001~5050) To rear ground To control box Red tape

Green tape

Throttle pedal (C0) Blue tape Air temperature probe (MCU) (Red tape) (C9)

To rear

Air temperature probe (air conditioner) (C8)

Hazard

Front working lamp

Fuel efficient mode change

Rear working lamp

Efficient loading system (option)

(Floor ground)

Option

Option Yellow tape

Declutch switch (B0)

Operation switch connection To operation stand

To rear

To T/M

Top view

To rear Horn switch (B8) Combination switch (B9)

Instrument panel, switch For diode unit (A0) (ZV2: S/N 5015~, TMV2: S/N 4011~)

Shift lever (B7)

To instrument panel, switch

Parking switch (B5)

Front

From operator’s seat 65ZV2/TMV2 03255-00572A US 1/2

K65V2U92026

65ZV-2 US 92-54 92 Drawing & Diagrams Electrical Equipment Layout Floor (control box) (S/N 5001~5050)

" 9 : ; =8< 9 : ;8 = #

. ! ! " # ! " #

" 9 : = ;< 9 : 8 ==;#

. ! ! " # ! " #

23 / ! 0 & "1 #

! " # !% &

4 & " 8#

! &' & & ( ) "* % ! ( ) + #

( % && 2 7 % / 0 & " & &#" # " 9 : ;< 9 : 8 ;#

$ . & " # "( & % #

4 ( ) " %(# 4 ( ) "/% &#

5 66 "7 # 4 & " 8#

5 66 "7 #

$ ! ! " # ! " #

/ ! 0 & "1 #

23 %/ ' &. 4 ( ) "/% &#

/ ! 0 & "1 #

4 ( ) " %(# $ ! " #

! && ": .#" #

" #

8 ! && * 3 " =#

* . % 1*

! && $ %'& ! && & " #

, % & ! && &

3 $% % & && " 8#

$ ! ! " #

$ && . && & ( )

4 & 23

! && ,. / & " # ( % && & " 8# ( && ",> #" =# " 9 : ; ?< 9 : ;8 #

5% '&% ",> # "7 &.# % ! "2= 2 # 4 ( ) "/% &#"$=;$ #

4 ( ) " %(#"$ ;$ # . & ! ( & "7=# 7 &

1! @ * .

$3 $3 &+ "2 8# ! ! . ! ",> # " . % # "7 # % & & " #

% &. & "C #

1! @ 5

+% + "7 ;78#

B 8 " &# . . (% -

8 ( % &&

8 ( &&

33 3 5* *

8 ! && 4 % ! &

5 @ 7 &

! && 23 /% & %-

5 @ 1!

% ! && &

! &&

* %- && &

65ZV-2 US 92-55 92 Drawing & Diagrams Electrical Equipment Layout Floor board (S/N 5051~) # & # 2

': ## 4 & # 2)

# !# # 0#> 7 2

" # 2 '/ ) #0 ' / ) '7 2 ) '/ )

#0 ' !# 2 # ) '/.)

- 1 2 ' 3 4 ) ' 3 45 ) 6 # ' 3 4) ' 3 5 4)

8 ( : # # % & 7 # % &

: ** ! #2 !" & ;** ! # 2 & < '# # )

': ## & # 2)

6 #

6 # 9 #

6 #

= ! !" !" '( )

6 # !" !# ! #

# # # 2 #

# +

# -# !" '(.) /# 0 # !" '( )

!" :# 2 #2 ' ) ' @ 3 4 @ 3 5 4)

" * + '(,)

# !"

$ % & !" '( )

: #

: # # # ?

65ZV-2 US 92-56 92 Drawing & Diagrams Electrical Equipment Layout Floor (control box) (S/N 5051~) / " ! " # $ ! " # $ + , & &' " #0 $ # 1 2$ # 1 3 2$

+ , & &' " #0 $ # 1 2$ # 1 3 2$

! " # $ "& '

8 ' # $ % / ' # $ #) ' &! $ <7 &4 ( '/ 4 !" ! 5 ' #6 $

9 :: #; $

7&! # 1 2$ 2$ 8 ' # $ # 1 3

" '( ' ' ) * #+ & " ) * , $

% " ! " # $ ! " # $

% " ! " # $ ! # $

% '' / '' ' ) *

+ , & &' # 1 2$ # 1 3 2$ > &!

; '

8 '

& " #< < $ 8 ) * #4& '$#% 2% $

6" = + /

8 ) * # &)$#% 2% $

4 '& &! # 1 2$ # 1 3 2$

9 = 6"

& " '' '

/ ' " ) ' #; $

-! & ' " '' '

77 7 9+

9 = ; '

#; '/$

+ / &!

6" = 9

%& & ' '' # 3$ ! " '' -/ 4 ' # $ ! ) & '' ' # 3$ 3 ! ) & '' # 1 2$ # 1 3 2$

% " ! " # $

+ , & &' " #0 $

! " '' #1 /$# $ 3 ! " '' + 7 # $ ! " '' 1 <7- ' # $ # 1 2$ # 1 3 2$ ! " '' % &(' " '' ' # $ # 1 2 $ # 1 23 $

# 1 2$ # 1 3 2$

3 ! ) ''

9& ('& #-? $

3 ! ) & ''

%7 %7 ', #< <3$ ! ,& , #; 2;3$

! " '' <7 4& ' &.

%7 %7 ', #< <3$

3 ! " '' 8 & " ' # ! '$ # 1 2$ # 1 3 2$

" " / " #-? $ # / &! $ #; $ & ! ' ' # $ & '/ ' #A A $

8 ) * # &)$

8 ) * # &)$ 8 ) * #4& '$

9 :: #; $

! ) & '' < ; & 4!5 ' # ' ! '$# $

8 ) * #4& '$

@ 3 ! # ! '$ / / )& .

# 1 2$ # 1 3 2$

! " '' 4 '& &! # 1 2$ # 1 3 2$ + &. '' '

65ZV-2 US 92-57 92 Drawing & Diagrams Electrical Equipment Layout

Floor board (S/N 5001~5050) F/R switch (OPT)

Rear working lamp S/W

(A4)

Spare power

(T3)

Horn S/W

Front working lamp S/W (B2)

Instrument panel

(B1)

Fuel efficient mode S/W

(A5

Parking S/W Shift lever

(A3)

Hazard S/W

(B9)

(A2)

Atmospheric press. sensor (W2)

(B5)

(A1) (A0) Diode unit (S/N 5015~)

MCU (S5~S9)

(B7) DC-DC converter (E3/E4) Fuse box (main) (D1~D5)

Fuse box (Cab) (D6~D0)

To control box (Air conditioner)

ECM

Air suspension (T5)

(W3~W5)

Starter S/W (H9) (H8)

Downshift S/W Outside air thermo sensor (MCU) (C9)

Resistor for E/G speed (W1)

(B8)

Combination S/W

ELS S/W

E/G water temp. sensor (for inspection) (S/N 5009~)

Pilot valve

(E2)

Buzzer Kickout setup S/W (T7)

(E1)

Fuse unit

Declutch setup S/W

(V4)

(T6)

(G6)

Odometer (S3) A/M S/W (S4)

(V3) (G1)

Electrical unit

(G2~G4) Shift hold S/W (option)(G9)

(C0)

Throttle pedal Declutch cutoff (B0)

(F0)

(OPT)

Emergency steering (option)(E8)

Power To T/M solenoid valve (H2)

To Cab

F/R S/W & stick steering (option)(E0)

To rear chassis

Reversing fan (option) (E5)

(H1)

(C1~C3) (C7) Declutch sensor

Ride control S/W (option) (E6)

To rear chassis

(H3~H6)

(H7) K65V2U92015

65ZV-2 US 92-58 92 Drawing & Diagrams Electrical Equipment Layout

3 6 /< !1% :"

Floor board (S/N 5051~)

6( < # $ 0 ( ' 0 0 <( 3 ! < # $ ' 0

. 9

@ /! - ( ! 0 ('

3-(' (&& 1 ( ! 9(

1# -! /(!-0 +

@ /! - ( ! 0 (' 5

; 9( - !

6(/ /! & 4 /0((9

" # $

! /0%( 1 0 (//2 /( /

A 3-/( = ; ;

3-/( = ; ;

1 ! ' = 1 9 ! ( /-/0( /

! !(

; < /% &! " ' ! ) ')(

5 +

:-!/ 9( !%( /( / 1 * 4

4 4 :"

% &! % '9 0! 4

% !!'( 0(9 '

, / '( 9 ) ')(

3 6 7 /! 1# /!(( $ 0!

( 1% // /

, + 5

5 6()( / $ & 0! 6 9( 1 ! ' 0!

( 1% // /

5 1 ! ''(

:9 (!(

( 1% // /

+ ;(1'-!1% /( /

3-/( -..( - !

( $( 18 /!(( $ 0! *

'(1! 1 ' - !

" <(

;(1'-!1% 1-! &&

+ ; >; 1 )( !(

:-!/ 9( !%( /( / ,

4 < !( !( 02 /( / 3

% &! '()(

;(1'-!1% /(!-0

5 6()( / ' & /(!-0 ?

65ZV-2 US 92-59 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Outline of MODM (Machine Operation Diagnostic Module) Operation [

[ ] button

] button

(Press)

Press and hold Engine fault log

Replacement monitor

(Press)

Machine fault log

Input/Output monitor Press and hold Press and hold

Press and hold

Input signal Display window

[

(step back)] button

[

(step forward)] button

Fault log monitor

(Press)

Unit conversion Information monitor

Current output

Press and hold Language select.

Output signal (Press)

Outside air temperature

(Press)

Specification setting monitor

Parameter setting monitor

Electric current output (FAN SOL)

Engine oil filter

Machine speed and engine speed

Fuel filter

Engine coolant temperature

Coolant filter

T/M oil temperature

T/C line filter

Hydraulic oil temperature

Hydraulic oil return filter

Odometer

Engine oil

Cycle

T/C and T/M oil

Hydraulic sys. press.

Axle gear oil

Voltage

Hydraulic oil

Hour meter

Group 2

Calendar

Output 6 group

Brake main pressure 2

Input 7 group

Replacement monitor screen

Information monitor screen

Specification setting monitor screen

Parameter setting monitor screen

Output signal screen

Current output screen

Input signal screen

Password input

Deceleration 1

Press and hold

All reset

Deceleration 2

Ride control 1

Output 1 group

Brake pedal pressure

Input 1 group

Ride control 2

Output 2 group

Steering pressure

Input 2 group

Boom angle

Group 1

Brake main pressure 1

80V2U92006

65ZV-2 US 92-60 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

& &( '

) * + " +

$ "

( , (S/N 5001~5014)

/ " , "

)

$ "

, - .,

! "

! " 3 .

# " $

! "

1 2 /

( ,

/ " ,

65ZV-2 US 92-61 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Information Monitor Hour Meter

Outside Temprature (Information Menu Initial Screen) 3 sec

Unit Conversion

Language Selection 2 sec Change No Change Active Error

Machine Speed / Engine Speed Unit Conversion

Active Error Odometer Press any button Replacing Time Comming

Cycle

Engine Coolant Temprature

Reset

Unit Conversion

Replace Pop Up

Reset Press any button Hydraulic System Oil Pressure

Transmission Oil Temprature

Unit Conversion (Pressure)

Unit Conversion

Specification Setting Monitor

Reset

Voltage

Hydraulic Oil Temprature Unit Conversion

Replace Monitor

Reset

Press any button:

Hour Meter

Odometer / Trip Meter Unit Conversion

(

Reset

Cycle

)

Reset

Outside Temperature

80V2U92008

65ZV-2 US 92-62 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Replacement Monitor Hydraulic Oil

Enigin Oil Filter Cartrige (Replace Monitor Initial Screen)

Engine Oil

Transmission & Torque Converter Oil

2 sec

2 sec Change No Change 2 sec

2 sec Change No Change

Timer Reset

2 sec Change No Change 2 sec

2 sec Change No Change

Press any button

Timer Reset

2 sec Change No Change

Information Monitor

2 sec Change No Change

2 sec Engine Oil Filter

Timer Reset 2 sec Change No Change Hydraulic Return Filter

Replace Pop Up

2 sec

Hydraulic Oil Timer Reset

Transmission & Oil Filter

Press any button Replacing Time Comming

2 sec

Axle Gear Oil Timer Reset

Coolant Filter

Active Error

Timer Reset

Fuel Filter

Active Error

2 sec

Fault Log Monitor

Timer Reset Press any button:

Timer Reset

(

)

2 sec Change No Change Engine Oil

2 sec Timer Reset 2 sec Change No Change

Transmission & Torque Conveter Oil

80V2U92009

65ZV-2 US 92-63 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Fault Log Monitor 2 sec Engine Fault Log

Machine Fault Log 2 sec

Active Fault Engine Fault Log Maximum

Machine Fault Log Maximum

Machine Fault Log 1 (Initial Screen for Machine Fault Log)

Engine Fault Log 1 (Initial Screen for Engine Fault Log)

2 sec

Replace Pop Up

2 seconds or more: Return after clear Return without clear Machine Fault Log 2

Press any button Replacing Time Comming (Timer 0)

Clear Fault Log

2 sec

Active Fault

Press any button Engine Fault Log 2

Clear Fault Log Replace Monitor

2 seconds or more: Return after clear Return without clear Machine Fault Log 3

2 sec

Engine Fault Log 3 Clear Fault Log Input/Output Monitor

2 seconds or more: Return after clear Return without clear Clear Fault Log

Press any button (

Maximum Machine Fault Log

2 sec

Maximum Engine Fault Log Clear Fault Log

)

Note When pressing the [ ] button to clear a fault code, password entry is required on the 65ZV-2 S/N 5123 and thereafter.

2 seconds or more: Return after clear Return without clear

Machine Fault Log 1

Engine Fault Log 1

80V2U92010a

65ZV-2 US 92-64 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Input/Output Monitor 2 sec Other Output

2 sec Input Signal

2 sec

Analogue Input 2 sec

Output Signal

2 sec Other Output

2 sec

DI Port 7

DI Port 1 (Initial Screen for I/O Monitor)

2 sec

Brake main press 2

Input Signal 2 sec

Active Error

DO Port 6

Active Error Press any button

Brake Pedal Output Oil Pressure

Fan Control Sol. Valve

DO Port 1

Replacing Time Comming Replace Pop Up Press any button Steering Oil Pressure

DI Port 2

DO Port 2

Fault Log Monitor

DI Port 3

Boom Angle

DO Port 3

Parameter Setting Monitor

Brake Main Pressure 1 Press any button (

Brake Main Pressure 2

DI Port 7

DI Port 1 Input Signal Screen

Brake Pedal Pressure Input Sensor Screen

)

DO Port 6

DO Port 1 Output Signal Screen

Cooling Fan Current Output

80V2U92011

65ZV-2 US 92-65 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Parameter Setting Monitor Power Control (Vni) Setting 2

Calendar

Deceleration Pervention Setting 1 (Initial Screen for Parameter Setting)

2 sec

Lower Kick Out Parameter Setting

Input/Output Monitor

2 sec Change No Change Deceleration Prevention Setting 2

2 sec

Lift Kick Out Specification Selection Monitor

Parameter Setting 2 sec Change No Change 2 sec

Ride Control Setting 1

2 sec

Calendar

Parameter Setting

2 sec Change No Change

2 sec Change No Change 2 sec

Ride Control Setting 2

Deceleration Prevention Setting 1

Parameter Setting 2 sec Change No Change Speed Meter Divide Setting 1

Parameter Setting

2 sec Parameter Setting 2 sec Change No Change

- SPEED METER DIV2 - TACHOGRAPH DIV1 - TACHOGRAPH DIV2 - EMG STEERING ON - EMG STEERING OFF - K-LEVER V1 - K-LEVER V2 - K-LEVER Vmax - K-LEVER i1 - K-LEVER i2 - K-LEVER imax

- TRACTION CONTROL F1 - TRACTION CONTROL DSsc - TRACTION CONTROL Isc - TRACTION CONTROL ti - TRACTION CONTROL SCv - TRACTION CONTROL SCeg - TRACTION CONTROL SCi - TRACTION CONTROL SCt - T/M CUT OFF IS - 2 STAGE DSon - POWER CONTROL TWni

The cursor flashes in a 1-second cycle. (lights for 0.5 second and lights off for 0.5 second). The cursor moves rightward. (upper right

lower left

lower right

upper left)

The cursor skips (digits/column) which can not be changed. Adding 1 to the value where the cursor is (0

Subtraciting 1 to the value where the cursor is. (9

Power Control (Vni) Setting 2

80V2U92012

65ZV-2 US 92-66 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Specification Setting Monitor (1/2) Program No. (Initial Screen for Specification)

Password Input The cursor moves rightward. (upper right

lower left

lower right

upper left).

The cursor moves leftward. (upper left

Password

lower right

lower left

upper right).

Adding 1 to the value where the cursor is. (

To confirm the change, press this button for 2 seconds or more. Password OK 2 sec

Press and hold

Kick down

F/R Shift

- Auto brake - Engine speed - Engine curve - Cooling fan - T/C oil temp. switch - E/G coolant temp. switch - E/G coolant temp. sensor - E/G oil press. switch - E/G oil press. sensor - Brake press. diff. switch

- Shift hold - Ride control - Emergency steering - K-Lever - Hydraulic press. increase - Traction control - Tachograph - Efficient loading sys. (ELS) - Lower kickout - Lift kickout

Brake oil level

Wheel type

All reset

Group 1

Group 2

Specification setting monitor screen

Group 2

Group 1

80V2U92013

65ZV-2 US 92-67 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Specification Setting Monitor (2/2) Program No. (Initial Screen for Specification)

Password Input The cursor moves rightward. (upper right

lower left

lower right

upper left).

The cursor moves leftward. (upper left

Password

lower right

lower left

upper right).

Adding 1 to the value where the cursor is. (

To confirm the change, press this button for 2 seconds or more.

Password OK 2 sec

All Setting Reset

All Setting Reset Press and hold

2 sec Change No Change Press and Press and hold hold Group 1 of Specification setting monitor screen

Press and hold

Parameter Setting Monitor

Group 2 of Specification setting monitor screen Specification Selection Press and hold

Specification item 24 2 sec

Specification Item 2

Specification item 23 2 sec

Specification Item 1

2 sec Change No Change

2 sec

Specification Item 4

Specification Selection

2 sec Change No Change - Ride control - Emergency steering - K-Lever - Hyd. press. increase Specification Item 15

2 sec

- E/G coolant temp. switch - E/G coolant temp. sensor - E/G oil pressure switch - E/G oil pressure sensor

Specification Item 22 Specification Selection

Specification Item 24

2 sec Change No Change 2 sec

2 sec Specification Selection

Specification Item 23

Specification Selection

2 sec Change No Change 2 sec

All Setting Reset

Specification Selection

2 sec Change No Change Specification item 2

The cursor flashes in a 1 second cycle.

2 sec Change No Change - Engine speed - Engine curve - Cooling fan - T/C oil temp. switch

- Traction control - Tachograph - Efficient loading sys. (ELS) - Lower kickout

Not returning to password screen

2 sec Change No Change Press and hold

2 sec

Specification Item 3

Information Monitor

Specification Selection

2 sec Change No Change Specification item 1 80V2U92014

65ZV-2 US 92-68 92 Drawing & Diagrams MODM: Input/Output Monitor - Input/Output Signal Correspondence Table

MODM: Input/Output Monitor - Input/Output Signal Correspondence Table 0

INPUT 1

Shift lever F

Shift lever R

Shift lever 1

Shift lever 2

Shift lever 3

Shift lever A

Shift-up

Shift-down

INPUT 2

Transmission pressure switch

Kick-down

Declutch switch

Declutch setup

Parking switch

Engine speed sensor selection (ECM output/sensor output)

A/M selection (automatic/manual)

Meter selection (speed meter/ tachometer)

INPUT 3

Speed meter dividing ratio selection (large size tire/small size tire)

F/R switch F

F/R switch R

Spare input

F/R switch selection ON/OFF switch

Stick steering (K-Lever) arm rest switch

Shift hold switch

Traction control switch

INPUT 4

Engine mode selection (economical/normal)

Spare input

Pressure increase switch

Ride control switch

Kickout setup

Odometer selection (only forward/forward and backward)

Efficient loading system (ELS) switch

Lower kickout switch

INPUT 5

Lower kickout setup

Spare input

Clear fault log

Alternator neutral point voltage

Spare input

Opt 1

Hydraulic oil level switch

Opt 2

INPUT 6

Brake differential pressure switch

Brake oil level switch

Engine oil pressure switch

Engine coolant temperature switch

Transmission oil temperature switch

Transmission oil filter switch

Air cleaner clogging switch

Radiator water level switch

INPUT 7

Fuel level 3/4

Fuel level 1/2

Fuel level 1/4

Fuel level 1/8

Fuel level F

Reversal fan

Auto fan reversal

Error log recall

OUTPUT 1

1st speed solenoid valve

2nd speed solenoid valve

3rd speed solenoid valve

4th speed solenoid valve

F solenoid valve

R solenoid valve

H solenoid valve

Brake solenoid valve

OUTPUT 2

D solenoid valve

LU solenoid valve

Ride control solenoid valve

Efficient loading system (ELS) selection solenoid valve

Alternate idle relay

Pressure increase solenoid valve

Reversal fan solenoid valve

Brake lamp

OUTPUT 3

Selection switch indicator lamp

Reversal fan indicator lamp

Brake oil pressure warning lamp

Engine oil pressure warning lamp

Engine coolant temperature warning lamp

Transmission oil temperature warning lamp

Transmission oil filter warning lamp

Air cleaner warning lamp

OUTPUT 4

Back lamp

Secondary steering motor relay

Hour meter driving

Engine curve selection 1 (torque)

Neutral relay

MCU failure relay

Kickout coil

Lower kickout relay

OUTPUT 5

Slip control indicator lamp

Auto shift indicator lamp

Neural indicator lamp

Auto brake indicator lamp

Central warning lamp

Radiator water level warning lamp

Steering oil pressure warning lamp

Fuel level F

OUTPUT 6

Fuel level 3/4

Fuel level 1/2

Fuel level 1/4

Fuel level E

Slip control selection

Engine curve selection 3 (ISC)

Engine curve selection 1 (droop)

Buzzer